1998-2005 Volkswagen Bora Service & Repair Manual
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Workshop Manual
Golf 1998 ➤
Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics
Engine ID
APK AQY AZH
Edition 07.2004
Service
Service Department. Technical Information
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List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
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.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg K0051007620
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.1 Notes on removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Notes on installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 Assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5 Additional information and removal instructions for vehicles with air conditioner . . . . . . . . 11
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Removing and installing sealing flanges and flywheel or drive plate . . . . . . . . . . . . . . . . . . 20
2.1 Renewing crankshaft oil seal - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.2 Removing and installing front sealing flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 Assembly overview - Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.2 Checking pistons, piston rings and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.1 Colour identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.1 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 Checking semi-automatic toothed belt tensioning roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2 Renewing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4 Checking hydraulic bucket tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.6 Renewing valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
1.2 Assembly overview - Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Assembly overview - Oil filter bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.4 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
1.5 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
Contents i
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1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.1 Parts of cooling system - body side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.2 Parts of cooling system - engine side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
1.3 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.4 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.5 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.6 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
1.7 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.1 Removing and installing fuel tank with attachments and fuel filter . . . . . . . . . . . . . . . . . . . . 89
1.2 Removing, installing and checking suction jet pump: vehicles with four-wheel drive . . . . . . 94
1.3 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.4 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.5 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.6 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.7 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
1.8 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.9 Checking fuel pump G23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
2 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.2 Repairing parts of activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.3 Checking solenoid valve 1 for activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . 111
2.4 Checking fuel tank venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3 Checking electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.2 Checking accelerator pedal position sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.1 Repairing accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.2 Adjusting throttle cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.1 Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.2 Vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
1.3 Checking catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.2 Removing and installing parts of secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
2.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
2.4 Checking secondary air pump motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
2.5 Checking secondary air inlet valve N112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
ii Contents
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00 – Technical data
1 Technical data
Engine number ⇒ page 1
Engine data ⇒ page 1
1.1 Engine number
The engine number (“engine code” and “serial number”) can be
found at the front on the joint between engine and gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
In addition, 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 sticker.
1.2 Engine data
Engine code APK AQY AZH
Manufactured 11.98 ▸ 11.98 ▸ 09.00 ▸
Emissions fulfil MVEG II D4 standard EU4 standard
Capacity l 2,0 2,0 2,0
Output kW at rpm 85/5200 85/5200 85/5400
Torque Nm at rpm 170/2400 170/2400 170/2400
Bore ∅ mm 82,5 82,5 82,5
Stroke mm 92,8 92,8 92,8
Compression ratio 10,5 10,5 10,5
RON min. 95 unleaded 95 unleaded 95 unleaded
Injection, ignition Motronic 5.9.2 Motronic 5.9.2 Motronic ME7.5
Knock control yes yes 2 knock sensors
Self-diagnosis yes yes yes
Lambda regulation yes yes 2 probes
Catalytic converter yes yes yes
Exhaust gas recirculation no no no
Turbocharging/supercharging no no no
Secondary air system no yes yes
Variable intake manifold no no no
Variable valve timing no no no
Electronic power control no no yes
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
1. Technical data 1
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10 – Removing and installing engine
1 Removing and installing engine
Special tools and workshop
equipment required
♦ Lifting tackle -2024 A-
♦ Engine bracket -T10012-
♦ Support clamp -VW 313-
♦ Engine and gearbox stand -
VW 540-
♦ Workshop hoist -V.A.G
1202 A- or workshop hoist -
VAS 6100-
♦ Drip tray -V.A.G 1306- or
drip tray for workshop hoist
-VAS 6208-
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
2 Rep. Gr.10 - Removing and installing engine
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♦ Torque wrench -V.A.G
1331- (5..50 Nm)
♦ Torque wrench -V.A.G
1332- (40...200 Nm)
♦ Engine and gearbox jack -
V.A.G 1383 A-
♦ Spring-type clip pliers -VAS
5024-
♦ Engine and gearbox sup‐
port supplement -VW 540/1
B-
♦ Step ladder -VAS 5085-
Not illustrated:
♦ Grease -G 000 100- (vehicles with manual gearbox)
♦ Bolt M10×25 / 8.8
♦ Cable ties
1.1 Notes on removing
Note
Before carrying out further work, disconnect battery earth strap.
First check whether a coded radio is fitted. Obtain radio code first
if necessary.
– The engine is removed downwards together with the gearbox.
– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
– With the ignition switched off, disconnect battery earth strap.
– Remove engine cover.
– Drain coolant ⇒ page 81 .
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
1. Removing and installing engine 3
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– Remove battery and battery retainer.
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
4 Rep. Gr.10 - Removing and installing engine
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– Pull off supply hose -1- (with white marking) and return hose
-2- (with blue marking) and catch fuel which escapes with a
cloth.
– Pull hose -3- off activated charcoal filter system solenoid valve
1 -N80- .
WARNING
Fuel system is under pressure! Before opening the system
place a cloth around the connection. Then release pressure by
carefully loosening the connection.
Note
Press buttons on hose couplings to do this.
– Seal lines so that fuel system is not contaminated by dirt.
– Observe rules for cleanliness ⇒ page 98 .
– Pull vacuum and breather hoses off engine.
– Remove noise insulation tray.
– Detach connectors from the following components:
♦ Ignition transformer -N152-
♦ Hall sender -G40-
♦ Injector for cylinder 1 -N30-
♦ Injector for cylinder 2 -N31-
♦ Injector for cylinder 3 -N32-
♦ Injector for cylinder 4 -N33-
♦ Coolant temperature sender -G62-
♦ Engine speed sender -G28-
♦ Oil level and oil temperature gauge -G266-
♦ Knock sensor 1 -G61-
♦ Knock sensor 2 -G66-
♦ Secondary air pump motor -V101-
♦ Oil pressure switch -F1-
♦ Air mass meter -G70-
♦ Throttle valve control module -J338-
♦ If necessary A/C system shutoff thermal switch -F163-
– Remove intake hose between air mass meter -G70- and throt‐
tle valve module -J338- ⇒ Rep. Gr. 24 .
– Remove air cleaner.
– Remove upper part of intake manifold: ⇒ Rep. Gr. 24 .
Note
Seal intake ports in the lower part of intake manifold using a clean
cloth.
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
1. Removing and installing engine 5
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– Unbolt selector mechanism from gearbox: ⇒ Rep. Gr. 34 .
– Remove hydraulic clutch slave cylinder: ⇒ Rep. Gr. 30 .
Vehicles with automatic gearbox:
– Remove selector lever cable from gearbox: ⇒ Rep. Gr. 37 .
Continuation for all vehicles:
– Remove poly V-belt ⇒ page 17 .
– Remove securing clamps for power steering pressure line.
– Unbolt power steering vane pump from bracket and place to
one side, hoses remain connected: ⇒ Rep. Gr. 48 .
Vehicles with air conditioning:
– Remove air conditioner compressor.
– Observe additional information and installation work
⇒ page 11 .
Continuation for all vehicles:
– Remove inter-connecting, coolant, vacuum and intake hoses
on engine.
– Remove secondary air pump and bracket.
– Disconnect all electric wires from gearbox, alternator and
starter and lay to side.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and lay clear.
– Disconnect pendulum support -arrows-.
– Remove inner right constant velocity joint protective cap from
engine.
Vehicles with four-wheel drive:
– Separate front propshaft from gearbox: ⇒ Rep. Gr. 39 .
Continuation for all vehicles:
– Remove right-hand drive shaft and unbolt left-hand drive shaft
from gearbox: ⇒ Rep. Gr. 40 .
– Remove front exhaust pipe ⇒ page 123 .
– Insert engine bracket -T10012- in engine and gearbox jack -
V.A.G 1383 A- .
– Fit engine bracket -T10012- to front of cylinder block with
M10x25/ 8.8 bolt.
– Tighten securing nut exhaust side by hand.
– Lift engine and gearbox slightly using engine and gearbox jack
-V.A.G 1383 A- .
Golf 1998 ➤ , Bora 1999 ➤
4-cyl. injection engine (2.0 ltr.), mechanics - Edition 07.2004
6 Rep. Gr.10 - Removing and installing engine
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A VW Bora 1998-2005 Workshop Service Repair Manual is an essential resource for anyone serious about maintaining their vehicle. Whether you're a professional mechanic or a DIY enthusiast, this manual provides detailed instructions for a wide range of maintenance tasks and repair projects, from simple to complex. It includes enriched text with photos and diagrams to guide you through diagnostic charts, troubleshooting guides, and in-depth information about the mechanical and electrical systems of your vehicle.
With this manual, you can easily perform routine maintenance tasks, MOT test checks, roadside repairs, and more. It covers engine and associated systems, cooling, heating, air conditioning, fuel and exhaust systems, engine electrical systems, emissions control systems, transmission, manual and automatic transmission, clutch, driveshafts, brakes, braking system, suspension, steering systems, body equipment, bodywork, fittings, electrical systems, wiring diagrams, tools, working facilities, general repair procedures, spare parts, vehicle identification numbers, fault finding, and a glossary of technical terms.
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