Exterior motor parts \/ measurements<\/strong><\/p>\n\n\n\nInjectors<\/p>\n\n\n\n
Bosch part number: 0-280-150-955
Fuel injector type: Top mount
Fuel injector CC\/Min: 176
Fuel injector Grams\/Min: 126.6
Fuel injector flow rate: 16.75
Fuel injector pressure: 36.25 PSI
Fuel injector impedance: High 12-16\u03a9<\/p>\n\n\n\n
Fuel Rail<\/p>\n\n\n\n
Part Number: 06A 133 317 R
Fuel rail inlet: passenger side
Fuel rail inside diameter: ($ \/ $$)
Fuel rail spacing: 88 mm between 1 and 2; 45mm between 2 and 3; 88mm between and 3 and 4<\/p>\n\n\n\n
Throttle body<\/p>\n\n\n\n
Bore: 2.4″
Throttle plate: 2.22″
OBD I: includes Dashpot and idle stabilization valve
OBD II: Integrated throttle position switch (replacing the I.S.V. and Dashpot)<\/p>\n\n\n\n
Intake Manifold<\/p>\n\n\n\n
:wave:[NOTE: OBDI External ISV attached to the exterior of the upper manifold.]<\/p>\n\n\n\n
OBD I
(Lower Intake)
Part Number:037 133 206 C
Lower runner length: 6.2″ long
Port inside diameter: 32.5mm (head side)
Port inside diameter: 34.5mm (opening connecting to upper manifold)
Single runner volume: 150cc<\/p>\n\n\n\n
(Upper Intake)
Part Number: 037 133 201 AQ
Port inside diameter: ($)
Runner length: ($)
Plenum Volume: ($)<\/p>\n\n\n\n
:wave:[NOTE: OBDII upper manfold included vanes immediately forward of where the individual ports begin.]<\/p>\n\n\n\n
OBD II
(Lower Intake)
Part Number:037 133 206 C
Lower runner length: 6.2″ long
Port inside diameter: 32.5mm (head side)
Port inside diameter: 34.5mm (opening connecting to upper manifold)
Single runner volume: 150cc<\/p>\n\n\n\n
(Upper Intake)
Part Number: 037 133 203 T
Port inside diameter: 34.25mm (opening connecting to lower manifold)
Runner length: 3.875″
Plenum Volume: 1.8L<\/p>\n\n\n\n
Exhaust Manifold
:wave:[Note: Some 1995 models will have OBDII exhaust manifolds]<\/p>\n\n\n\n
OBDI
Part Numbers: 037 253 031 AP (Early Years, Non-Emissions) ; 037 253 031 AL (Mid Years, and California) ; 037 253 031 BP (Late years and all Canada)
Material: Cast
Type: 2 piece; 4-2-1
Upper Manifold Runner Size:
Lower Manifold Runner Size:
Collector Diameter: 2.25in
Exhaust Manifold Stud: 8X47mm<\/p>\n\n\n\n
OBDII
Part Number: 037 253 031 L ; 037 253 031 cc (California)
Material: Cast
Type: 2 piece; 4-2-1
Upper Manifold Runner Size:
Lower Manifold Runner Size:
Collector Diameter: 2.25in
Exhaust Manifold Stud: 8X47mm.<\/p>\n\n\n\n
MAF sensor<\/p>\n\n\n\n
VW part number: 037-906-461-A
Bosch part number: 0-280-217-103
MAF sensor Housing size: 2.75″<\/p>\n\n\n\n
Camshaft Sprocket<\/p>\n\n\n\n
Sprocket Part Number: 049 109 111 c
Geer Length: xxx Teeth<\/p>\n\n\n\n
Spark plugs \/ wires<\/p>\n\n\n\n
Part Number:
Spark plug gap: .028 (also listed, .024 and .026, anyone have VW’s spec?)
Spark plug wire size: 7mm<\/p>\n\n\n\n
Thermostat<\/p>\n\n\n\n
Part Number: 044 121 133
Opening temp: 185*
Fully open temp: 221*<\/p>\n\n\n\n
Electric Cooling Fans
:wave:[Note: All temperatures measured in F.]
:wave:[Note: There is a second switch that controls a stage 3 fan speed fitted into one of the cooling housings on the cylinder head. This is only applicable on certain models]<\/p>\n\n\n\n
Part Number: 1H0 959 455 (no AC) \/ 1HM 959 455 C (with AC) \/ 165 959 455 L (either)
Fan Size: 305mm (first two pn’s) \/ 280mm (last pn)<\/p>\n\n\n\n
Stage 1 on: 198* – 207*
Stage 1 off: 183* – 196*<\/p>\n\n\n\n
Stage 2 on: 210* – 221*
Stage 2 off: 196* – 208*<\/p>\n\n\n\n
Stage 3 on: 230* – 239*
Stage 3 off: 221* – 230*<\/p>\n\n\n\n
Alternator<\/p>\n\n\n\n
Part Numbers (Valeo): 028 903 025 P \/ 037 903 023 G (+a\/c)
Part Numbers (Bosch): 028 903 025 P \/ 028 903 025 Q (+a\/c)
Pulley Diameter: 49mm (1.929 in)
Regulator Plug Clocking: 8.00
Voltage: 12 volt, Negative ground
Amperage: 90
Minimum brush length<\/p>\n\n\n\n
Radiator<\/p>\n\n\n\n
dimensions: 675mm x 675mm x 322mm<\/p>\n\n\n\n
Expansion Tank<\/p>\n\n\n\n
Cap opening pressure: 19-23 psi<\/p>\n\n\n\n
Distributor<\/p>\n\n\n\n
Part Number: 037 905 237 BX \/ 037 905 205 T
Type: Breakerless
Ignition Timing: Controlled by EMS
Firing order: 1-3-4-2
Rotation: Clockwise<\/p>\n\n\n\n
Ignition System<\/p>\n\n\n\n
1993-1995
Bosch Motronic M2.9<\/p>\n\n\n\n
1996-1999
Bosch Motronic M5.9<\/p>\n\n\n\n
Coil<\/p>\n\n\n\n
Primary resistance: 0.5\u03a9 to 0.7\u03a9
Secondary resistance: 2 k\u03a9 to 4 k\u03a9<\/p>\n\n\n\n
Water pump<\/p>\n\n\n\n
Part Number: 037 121 005 C (housing with impeller) \/ 037 121 010 C (water pump with sealing washer; without pulley, thermostat, and adapter (gooseneck))<\/p>\n\n\n\n
PCV valve<\/p>\n\n\n\n
Part Number: 037 129 101 H \/ 037 129 101 R<\/p>\n\n\n\n
Vacuum brake booster<\/p>\n\n\n\n
Part Number: 1H1 612 107 C (w\/out ABS) \/ 1H1 612 107 D (w\/ ABS)<\/p>\n\n\n\n
Master Cylinder<\/p>\n\n\n\n
Part Number: 357 611 019 B (w\/out ABS) \/1H1 698 019 B (w\/ ABS)<\/p>\n\n\n\n
A\/C compressor<\/p>\n\n\n\n
Part Number: 1H0 820 803 D
High side Psi: 205.0
Low side Psi: 17.0<\/p>\n\n\n\n
Fluids \/ fluid measurements<\/strong><\/p>\n\n\n\nOil<\/p>\n\n\n\n
Oil type: API grade SH or SH\/CD multi-grade oil
Maximum oil capacity (including filter): 4.2 Quarts
Oil Viscosity: 5w40 or 10w40 (viscosity is temperature dependent, other oils may be applicable)<\/p>\n\n\n\n
Fuel<\/p>\n\n\n\n
Fuel type: Gasoline
Fuel octane: All standard octanes acceptable
Fuel pressure (regulated): 36 psi
Maximum fuel capacity: 14.5 gallons<\/p>\n\n\n\n
Coolant
:wave:[Note: NEVER EVER cross mix different color anti-freeze.]<\/p>\n\n\n\n
Coolant type: 50\/50 mixture of water and coolant
OBDI maximum coolant capacity: 5.8 Quarts
OBD II maximum coolant capacity: 6.1 Quarts<\/p>\n\n\n\n
Automatic Transmission Fluid<\/p>\n\n\n\n
Trans fluid type (1994 and earlier): DEXRON II
Trans fluid type (1995 and later): VW transmission fluid ONLY
Maximum trans fluid capacity: 3.2 Quarts
VW transmission fluid part number: G 052 162 A1 or G 052 162 A2<\/p>\n\n\n\n
Brake Fluid<\/p>\n\n\n\n
brake fluid type: DOT 4
maximum brake fluid capacity: ($ \/ $$)<\/p>\n\n\n\n
Power Steering<\/p>\n\n\n\n
Power steering fluid (Recommended): VW PS fluid (the regular stuff will do)
Power steering fluid capacity: 1.6 Quarts
VW PS fluid part number: g002000 or G002012<\/p>\n\n\n\n
Air Conditioning<\/p>\n\n\n\n
A\/C oil type: r134
Maximum A\/C fluid capacity: 28 oz of R134a – 3.9 oz (total) of PAG based oil<\/p>\n\n\n\n
Transmission<\/strong><\/p>\n\n\n\n5 speed manual<\/p>\n\n\n\n
Transmission code: 020
transmission type: DFQ. CHE, or AMC
Main shaft: 24mm (after June 1st, 1997, shafts are 22mm)
speedometer gear: 15T
1st gear ratio: 3.455
2nd gear ratio: 1.94
3rd gear ratio: 1.28
4th gear ratio: 0.97
5th gear ratio: 0.80
final drive: 3.67<\/p>\n\n\n\n
Automatic<\/p>\n\n\n\n
Transmission type: CLK, CFH, CFF
Number of gears:
Dimensions
Gear ratios:<\/p>\n\n\n\n
Fuse Box \/ Relays<\/p>\n\n\n\n
:wave:[Note: The crappy diagram I have drawn shows the layout of the relays as you are facing them]<\/p>\n\n\n\n
Location: Drivers side, under dash, above clutch pedal<\/p>\n\n\n\n
[19] [20] [21] [22] [23] [24]
[13] [14] [15] [16] [17] [18]
——————————–
[ 1 ] [ 2 ] [ 3 ] [ 4 ] [ 5 ] [ 6 ]
[ 7 ] [ 8 ] [ 9 ] [10] [11] [12]<\/p>\n\n\n\n
1 air conditioning system
2 rear wiper\/washer
3 fuel inchection\/ignition system
4 Load reduction
5 not used
6 emergency flasher
7 not used
8 Windshield wiper\/washer
9 Seat belt warning system\/control unit
10 Foglights
11 Horn
12 Fuel pump
13 Heated oxygen sensor control module (o2 sensor)
14 Park\/Neutral position
15 – 24 Optional equipment (does anyone have the relay equipment information for these?)<\/p>\n\n\n\n
non categorized stuff<\/strong><\/p>\n\n\n\nCylinder Head Bolts diagram and torque specs<\/p>\n\n\n\n
tighten in the following order:
_____________________
10…..4……2……6……8<\/p>\n\n\n\n
7……5……1……3……9<\/p>\n\n\n\n
stage 1 30ft\/lb
stage 2 44ft\/lb
stage 3 additional 90 Degree turn
stage 4 additional 90 Degree turn<\/p>\n\n\n\n
Torque specs (ft\/lbs unless otherwise stated)<\/strong><\/p>\n\n\n\nLISTED ALPHABETICALLY<\/p>\n\n\n\n
Air temperature sensor: 84 in-lbs
Alternator mounting bolts: 18
Camshaft bearing cap nuts\/bolts: 15
Crankshaft main bearing cap bolts: 48
Engine crossmember-to-body bolts:37
Exhaust manifold bolts: M8 bolts = 18 ; m10 bolts = 30
Flywheel mounting bolts: 44
Fuel rail mounting bolts: 84 in-lbs
Intermediate shaft flange bolts: 18
Intermediate shaft sprocket bolt: 59
Lock carrier-to chassis bolts: 17
Lock carrier to fender screws: 48 in-lbs
Intake manifold to head (lower): 18
Intake manifold to lower intake (upper) = 15
Lug Nuts (wheel bolts): 81
Oil cooler nut: 18
Oil pan drain plug: 22
Oil pump cover bolts: 84 in-lbs
O2 sensor (heated oxygen sensor): 37
Piston oil jet\/pressure relief valve: 19
Rod bearing cap bolts\/nuts : 22
Spark plugs: 22
Starter mounting bolts: Lower 33 ; Upper 44 ; Stud 44
Throttle body through-bolts: m6 bolts = 84 in-lbs ; m8 bolts = 15 ft-lbs
Timing belt tensioner bolt: 33
Transmission bell housing to engine: m10 bolts = 44; m12 bolts = 59<\/p>\n\n\n\n
Taken from VWVortex and put here so I won’t lose it.<\/p>\n","protected":false},"excerpt":{"rendered":"
Notations:[ $ = OBD I information has not yet been collected ][ $$ = OBD II information has not yet been collected ][ *** = information has not been verified by any technical data or a reliable source ] ——————- General (w\/5 speed manual transmission) Motor: 2.0L (1984 cc) I4 SOHC 8V Fuel Injected (121.071 cu … <\/p>\n
Read More Read More<\/span><\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[1],"tags":[],"class_list":["post-648","post","type-post","status-publish","format-standard","hentry","category-uncategorized"],"jetpack_featured_media_url":"","jetpack_sharing_enabled":true,"jetpack_shortlink":"https:\/\/wp.me\/p46pud-as","jetpack-related-posts":[],"_links":{"self":[{"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/posts\/648","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/comments?post=648"}],"version-history":[{"count":1,"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/posts\/648\/revisions"}],"predecessor-version":[{"id":649,"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/posts\/648\/revisions\/649"}],"wp:attachment":[{"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/media?parent=648"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/categories?post=648"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/chrisfaulkner.org\/index.php\/wp-json\/wp\/v2\/tags?post=648"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}