2001 VOLKSWAGEN CABRIO All Models Service and Repair Manual

2001 VOLKSWAGEN SERVICE AND MANUAL REPAIR

1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta GENERAL, TECHNICAL DATA TECHNICAL DATA Engine code The engine code and engine number (serial number) are die-stamped on the front of the cylinder block above the crankcase breather. In addition, an adhesive label on the drive belt cover lists the engine code and engine number. The engine code is also listed on the vehicle identification sticker in the luggage compartment. 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

Fig. 1: Locating Engine Code Courtesy of VOLKSWAGEN OF AMERICA, INC. Engine specifications (Golf, GTI, Jetta) ENGINE SPECIFICATIONS (GOLF, GTI, JETTA) Engine Code ABA ABA ABA Manufactured from: 07.92 08.95 08.95 Manufactured :to: 07.95 - - Displacement : liters 2.0 2.0 2.0 Output : Hp (kW) @ RPM 115 (85) @ 5400 115 (85) @ 5400 115 (85) @ 5400 Torque Ft lb (Nm) @ RPM 165 (122) @ 3200 165 (122) @ 3200 165 (122) @ 3200 Bore : mm (in.) 82.5 (3.248) 82.5 (3.248) 82.5 (3.248) Stroke : mm (in.) 92.8 (3.653) 92.8 (3.653) 92.8 (3.653) Compression ratio 9.6: 1 9.0: 1 9.0: 1 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

Engine specifications (Cabrio) ENGINE SPECIFICATIONS (CABRIO) Fuel requirement : RON (minimum) 91 lead-free 91 lead-free 91 lead-free Fuel injection system Motronic Multiport Fuel Injection (MFI) Motronic M5.9 Multiport Fuel Injection (MFI) Ignition system Motronic Motronic M5.9 Knock control Yes Yes Yes On Board Diagnostic (OBD) Yes OBD II (Tier 1) OBD II (T-LEV) Oxygen Sensor (O2S) control Yes (1 sensor) Yes (2 sensors) Three way catalytic converter (TWC) Yes Yes Yes Exhaust Gas Recirculation (EGR) Yes No No Secondary Air Injection (AIR) No No Yes Enhanced EVAP system No Yes Yes Leak Detection Pump (LDP) No Yes (1) Yes (1) (1) Not installed on all vehicles during m.y. 1996; not operational on vehicles up to 10.95. Engine code ABA ABA Manufactured from: 01.94 08.95 Manufactured to: 07.95 - Displacement : liters 2.0 2.0 Output : Hp (kW) @ RPM 115 (85) @ 5400 115 (85) @ 5400 Torque : Ft lb (Nm) @ RPM 165 (122) @ 3200 165 (122) @ 3200 Bore : mm (in.) 82.5 (3.248) 82.5 (3.248) Stroke : mm (in.) 92.8 (3.653) 92.8 (3.653) Compression ratio 9.4:1 9.4:1 Fuel requirement : RON (minimum) 91 lead-free 91 lead-free Fuel injection system Motronic Multiport Fuel Injection (MFI) Motronic M5.9 Multiport Fuel Injection (MFI) Ignition system Motronic Motronic M5.9 Knock control Yes Yes On Board Diagnostic (OBD) Yes OBD II (Tier 1) Oxygen Sensor (O2S) control Yes (1 sensor) Yes (2 sensors) Three way catalytic converter (TWC) Yes Yes Exhaust Gas Recirculation (EGR) Yes No Secondary Air Injection (AIR) No No 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

ENGINE - ASSEMBLY ENGINE, REMOVING AND INSTALLING Safety precautions Rules of cleanliness 1. Thoroughly clean fuel system line and hose connections and the surrounding area before disconnecting. 2. Place removed components on a clean surface and cover. Use plastic sheeting or paper. Do not use fluffy rags that could leave lint! 3. Carefully cover over or seal any components that have been opened if repairs are not carried out immediately. 4. Install only clean parts:  Do not remove replacement parts from the packaging until immediately before they are to be installed.  Do not use parts that have been stored without packaging (e.g. in toolboxes, etc.). 5. When the fuel system is opened: Enhanced EVAP system No No Leak Detection Pump (LDP) No No WARNING: Be sure the ignition is switched OFF, when:  Disconnecting ignition wires  Disconnecting fuel injection system wiring  Connecting or disconnecting test equipment leads  Disconnecting the battery  Washing the engine or engine compartment CAUTION: BEFORE disconnecting the battery:  Stop the engine.  Be sure the ignition is switched OFF (also applies when connecting the battery). Failure to do so may damage the Engine Control Module (ECM).  Be sure you have the proper radio code (for vehicles equipped with anti-theft radio). CAUTION: Whenever carrying out any work on the fuel supply or fuel injection systems, always observe the following rules of cleanliness. 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

 Avoid working with compressed air whenever possible.  Avoid moving the vehicle if possible. Engine, removing The engine is removed by moving it toward the front together with the transmission.  Ignition switched off  Disconnect battery Ground (GND) strap.  Drain engine coolant, see COOLING SYSTEM, DRAINING AND FILLING .  Remove two lock bolts that fasten radiator at upper radiator support.  Remove lock carrier (upper radiator support) with attached parts. For Golf, Jetta or GTI, see LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING . For Cabrio, see LOCK CARRIER, REMOVING AND INSTALLING . Vehicles with A/C For additional information and removing/installing instructions, see VEHICLES WITH A/C .  Disconnect power steering pump with bracket and lay it to the side. Vehicles with manual transmission  Disconnect clutch cable See CLUTCH CABLE, REMOVING AND INSTALLING .  Attach engine sling to shop crane as follows: Drive belt side: NOTE: All tie wraps that are loosened or cut during engine removal must be put back on in the same place when the engine is installed. CAUTION: Before disconnecting the battery, determine the correct coding for the anti-theft radio. CAUTION: DO NOT disconnect power steering hoses. See POWER STEERING PUMP, RESERVOIR AND HYDRAULIC LINES, SERVICING . 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

 2nd hole up from hook in cross bar position -1- Fig. 2: Attaching Engine Sling To Shop Crane Courtesy of VOLKSWAGEN OF AMERICA, INC. Flywheel side:  2nd hole up from hook in cross bar position -7- Vehicles with automatic transmission  Remove drive belt, see DRIVE BELT, REMOVING, INSTALLING AND ADJUSTING TENSION .  Remove crankshaft pulley/vibration damper.  Remove coolant pulley pump.  Install engine sling as follows and raise slightly with shop crane: Drive belt side: CAUTION: Use cotter pins on hooks and pins. NOTE:  The end of the cross bar marked with installation positions 1-4 points toward drive belt.  Holes in the hooks are counted from the hook end. 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

 4th hole up from hook in cross bar position -1- Flywheel side:  2nd hole up from hook in cross bar position -6- Fig. 3: Installing Engine Sling Courtesy of VOLKSWAGEN OF AMERICA, INC. All vehicles  Remove engine mount and lift engine together with transmission out toward the front. For engine repairs, mount engine in engine stand with VW540 holding fixture. CAUTION: Use cotter pins on hooks and pins. NOTE:  The end of the cross bar marked with installation positions 1-4 points toward drive belt.  The holes in the hooks are counted from the hook end. CAUTION: Lift unit out carefully to avoid damage to body. 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

Engine, installing  Install in reverse order of removal, noting the following:  Lightly lubricate transmission input shaft splines with G 000 100 grease.  Check whether guide sleeves for centering engine and transmission are in cylinder block; if not, install.  During installation of engine and transmission be sure to maintain clearance for drive shafts. When installing the engine mounts, the recesses on the right rear engine mount bracket and front engine mount must engage in the guide pins of the bonded rubber mounts (arrows).  Relieve tension on engine mounts by shaking engine.  Install lock carrier and attachments. Fig. 4: Identifying Engine Mounts Courtesy of VOLKSWAGEN OF AMERICA, INC. 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

For Golf, GTI or Jetta, see LOCK CARRIER WITH ATTACHMENTS, REMOVING AND INSTALLING . For Cabrio, see LOCK CARRIER, REMOVING AND INSTALLING .  Install power steering pump See POWER STEERING PUMP, INSTALLING .  Install A/C compressor A/C COMPRESSOR BRACKET, REMOVING AND INSTALLING - SANDEN COMPRESSOR (ENGINE CODES ABA, ACC) .  Fill coolant. See COOLING SYSTEM, DRAINING AND FILLING .  Connect clutch cable See CLUTCH CABLE, REMOVING AND INSTALLING .  Adjust accelerator cable. See ACCELERATOR PEDAL CABLE, ADJUSTING .  Perform closed throttle position testing (basic settings). For 1993-1995 models, see FUNCTION 04, "BASIC SETTING," INITIATING . For 1996-1999 models, see CHECKING CLOSED THROTTLE POSITION (CTP) SWITCH .  Adjust headlights, if necessary See HEADLIGHTS, ADJUSTING .  Electrical connections and routing  Tightening torques, see TIGHTENING TORQUES and ENGINE/TRANSMISSION MOUNTS, TIGHTENING TORQUES . Tightening torques TIGHTENING TORQUES (ENGINE REMOVAL/INSTALLATION) CAUTION: There are two different types of coolants. They are not interchangeable and must never be mixed warnings and cautions. See COOLING SYSTEM, DRAINING AND FILLING . Fastener connection Tightening torque Engine to transmission M10 60 Nm (44 ft lb) 2001 Volkswagen Cabrio GL 1993-2002 ENGINE 2.0L 4-Cyl 2V Engine Mechanical - Engine Code: ABA - Cabrio, Golf, GTI & Jetta

2001 VOLKSWAGEN CABRIO All Models Service and Repair Manual

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