Volkswagen Passat 1995 Operating instructions

ProCarManuals.com

2.0 Liter 4-Cyl. 2V Engine Mechanical, Engine Code(s): ABA m.y. 1995

00 - General, Technical data

Technical data

Engine numbers, location

Engine technical data

10 - Engine - Assembly

Engine, removing and installing

Removing

Installing

Tightening torques

Engine and transmission, aligning

Rubber bushings for engine mount, replacing

Vehicles with A/C, additional information on removing and installing

13 - Engine - Crankshaft, Cylinder block

Engine disassembling and assembling

Ribbed drive belt, removing and installing

Toothed drive belt, removing and installing

Sealing flange and flywheel or drive plate, removing and installing

Crankshaft oil seal (pulley end), replacing

Drive plate, removing and installing

Crankshaft, removing and installing

Crankshaft dimensions

Pistons and connecting rods, disassembling and assembling

Piston and cylinder dimensions

15 - Engine - Cylinder head, Valvetrain

Cylinder head removal and installation

Cylinder head, installing

Compression pressure, checking

Cylinder head, disassembling and assembling

Valve seats, refacing

Camshaft oil seal, removing and installing

Camshaft, removing and installing

Hydraulic valve lifters, checking

Valve guide wear, checking

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Valve guides, removing and replacing

Valve stem seals, replacing

17 - Engine - Lubrication

Lubrication system, general information

Lubrication system, components

Oil pressure and oil pressure switches, checking

19 - Engine - Cooling system

Cooling system

General information

Cooling system components, body side

Cooling system components, engine side

Coolant pump, disassembling and assembling

Cooling system, draining and filling

Radiator and coolant fan, removing and installing

20 - Fuel Supply

Fuel supply system

General information

Fuel filter and fuel tank with attaching parts, removing and installing

Safety precautions

Rules of cleanliness

Accelerator pedal cable, adjusting

Fuel pump module, removing and installing

Fuel pump, checking

Fuel pump delivery rate, checking

Evaporative Emissions (EVAP) system

Components, removing and installing

Fuel tank breather, checking

26 - Exhaust system, Emission controls

Exhaust system removal and installation

Exhaust manifold, front exhaust pipe and Three Way Catalytic Converter (TWC),

removing and installing

Muffler assembly and mounts

Exhaust Gas Recirculation (EGR) system

Exhaust Gas Recirculation (EGR) valve and EGR temperature sensor, checking

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Secondary Air Injection (AIR) system

Function

Secondary Air Injection (AIR) system components, removing and installing

Combi-valve and check valve, checking

Secondary Air Injection (AIR) pump motor, checking

Secondary Air Injection (AIR) solenoid valve, checking

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00-1

Technical data

Engine numbers, location

The engine numbers ("engine code"

and "serial number") are die-stamped in

the front of the cylinder block above the

crankcase breather.

In addition, there is a label with the

"engine code" and "serial number" on

the drive belt cover.

The engine code is also included on the

vehicle data plate.

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00-2

Engine technical data

Engine code ABA ABA

Manufactured from:

to:

03.95

07.95

08.95

Displacement liters 2.0 2.0

Output kW at RPM

HP at RPM

85 at 5400

115 at 5400

85 at 5400

115 at 5400

Torque Nm at RPM

Ft. lb at RPM

165 at 3200

122 at 3200

165 at 3200

122 at 3200

Bore mm 82.5 82.5

Stroke mm 92.8 92.8

Compression ratio 9.4:1 9.4:1

RON minimum 91 lead free 91 lead free

Fuel injection Motronic

multiport fuel injection

Motronic

multiport fuel injection

Ignition Motronic Motronic

Knock control Yes Yes

On Board Diagnostic system OBD OBD II

Oxygen sensor control 1 Oxygen Sensor 2 Oxygen Sensors

Three way catalytic converter Yes Yes

Exhaust gas recirculation (EGR) Yes No

Secondary Air Injection system Yes Yes

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10-1

Engine, removing and

installing

Special tools, testers and auxiliary items

Engine sling 2024 A

G 000 100 grease

Torque wrench VAG 1331: 5-50 Nm (4-

37 ft lb)

Torque wrench VAG 1332: 40-200 Nm

(30-148 ft lb)

Cable ties

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10-2

Removing

The engine is removed by moving it toward the

front together with the transmission.

CAUTION!

Determine correct radio anti-theft coding

before disconnecting the battery.

Ignition switched off.

- Disconnect battery negative cable (ground

strap).

Note:

All tie wraps that are loosened or cut during

engine removal must be replaced when the

engine is installed.

- Remove air cleaner housing with intake air

ducts.

- Loosen power steering reservoir hose clamp.

- Disconnect power steering pressure line clamps

from subframe and transmission.

- Remove power steering pump with bracket and

lay it to the side; power steering hoses remain

connected.

Repair Manual, Suspension, Wheels, Brakes,

Steering, Repair Group 48.

- Drain engine coolant Page 19-9

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10-3

- Remove lock carrier (upper radiator support)

with attached parts.

Repair Manual Body Exterior, Interior, Repair

Group 50

- Remove coolant fan and fan shroud.

Vehicles with A/C:

- Refer to additional information and removal

instructions Page 10-14 .

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