Volkswagen 2.8L Golf Specifications

2.8L VR6

Article Text

This file passed thru Volkswagen Technical Site - http://volkswagen.msk.ru

ARTICLE BEGINNING

1999-2000 ENGINES
Volkswagen 2.8L VR6 6-Cylinder

Golf, GTI, Jetta

* PLEASE READ THIS FIRST *

NOTE: For engine repair procedures not covered in this article,
see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article
in the GENERAL INFORMATION section.

ENGINE IDENTIFICATION

Engine identification number is stamped on a machined pad, on
front of the cylinder block. See Fig. 1. The engine code is also
listed on a sticker attached to the pulley side of the valve cover and
the vehicle identification sticker located in the luggage compartment.

ENGINE CODES

ДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДД

Application Code

2.8L VR6 ...................................................... AAA

2.8L VR6 ...................................................... AFP

ДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДДД

Fig. 1: Locating Engine Identification Number
Courtesy of Volkswagen United States, Inc.

ADJUSTMENTS

VALVE CLEARANCE

Engine is equipped with hydraulic lifters. Adjustment is not
necessary.

TROUBLE SHOOTING

NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL TROUBLE SHOOTING section.

REMOVAL & INSTALLATION

* PLEASE READ THIS FIRST *

NOTE: When battery is disconnected, vehicle computer and memory
systems may lose memory data. Driveability problems may exist
until computer systems have completed a relearn cycle.

NOTE: For reassembly reference, label all electrical connectors,
vacuum hoses and fuel lines before removal. Also place mating
marks on other major assemblies before removal.

WARNING: Radio/cassette or radio/CD player is equipped with an
anti-theft protection circuit. Whenever battery is
disconnected, radio will go into anti-theft mode. When
battery is reconnected, radio will display CODE, and will be
inoperative until proper code number is entered. Obtain
security code before disconnecting battery.

FUEL PRESSURE RELEASE

Remove fuel pump relay (lower right relay located in
fuse/relay panel). start engine and let idle until it stalls. Crank
engine for an additional 5 seconds. Reinstall fuel pump relay.

ENGINE

NOTE: Engine is removed with transaxle attached.

Removal

1) Obtain radio code. Turn ignition off and wait 20 seconds.
Disconnect negative battery cable. Remove air cleaner assembly.
Install 8-mm bolt in belt tensioner hole and remove accessory drive
belt. See Fig. 2.

2) On manual transmission models, disconnect clutch slave
cylinder. On all models, remove power steering pump and attach to
body. DO NOT disconnect power steering hoses. Remove radiator, front
lock support and front bumper. Drain cooling system. Disconnect
cooling fan and thermoswitch.

Fig. 2: Releasing Accessory Drive Belt Tensioner
Courtesy of Volkswagen United States, Inc.

3) Label and disconnect all electrical wiring, control
cables, coolant hoses and vacuum hoses from engine/transaxle assembly.
Disconnect throttle, cruise and kickdown linkage (if equipped). Remove
air duct from intake manifold.

4) Disconnect drive axles from transaxle. See FWD AXLE SHAFTS

article in DRIVE AXLES. Disconnect exhaust pipe from exhaust manifold.
Attach Engine Sling (2024A). See Fig. 3.

5) Disconnect left rear transaxle mount and right rear engine
mount. Disconnect front engine mount. Release engine carrier. It may
be necessary to pry spacer bracket from rubber bushings. Raise engine
and transaxle out of vehicle.

Installation
To install, reverse removal procedure. Use NEW self-locking
nuts and coolant. Ensure engine mounts are installed to original
location. Align all engine supports with mount bushings before
tightening mount bolts. Tighten bolts to specification. See
TORQUE SPECIFICATIONS.

Fig. 3: Attaching Engine Sling
Courtesy of Volkswagen United States, Inc.

INTAKE & EXHAUST MANIFOLD

Removal and installation procedure is not available from
manufacturer. See TORQUE SPECIFICATIONS.

CYLINDER HEAD

Removal (GTI & Jetta - AAA Engine)

1) Remove upper engine cover. Remove wire guide. Remove right
rear support between upper intake manifold and cylinder head. Remove
fuel line bracket, flame trap coil and circlip. Remove wire brackets.
Remove valve cover and gasket. See Fig. 4.

Fig. 4: Identifying 2.8L VR6 Cylinder Head (GTI & Jetta - AAA Engine)
Courtesy of Volkswagen United States, Inc.

2) Remove camshaft position sensor, "O" ring and spacer ring.
Remove bracket for 42-pin connector and water pump. Remove ignition
coil, chain tensioner and seal. Remove camshaft sprocket cover. Remove
cylinder head bolts in reverse order of installation. See Fig. 7.
Replace cylinder head bolts after loosening or removing.

Removal (Golf & Jetta - AFP Engine)

1) Remove engine cover. Remove upper intake manifold, fuel
line retainer, cylinder head and gasket. Remove Coolant Return Pump
(V51) and retainer. See Fig. 5. Remove ignition coil bolt and ignition
coil from cover.

2) Remove "O" ring, chain tensioner and seal ring from cover.
Remove cover bolts and cover from cylinder head. Remove thermostat

housing retainer, seal, thermostat housing, O-ring and combination
valve from cylinder head.

3) Remove lower intake manifold bolts, both upper and lower
seals, and lower intake manifold. Remove cylinder head bolts in
reverse order of installation. See Fig. 7. Replace cylinder head bolt
after loosening or removing.

Fig. 5: Identifying 2.8L VR6 Cylinder Head (Golf & Jetta - AFP
Engine)
Courtesy of Volkswagen United States, Inc.

Inspection
Thoroughly clean all gasket mating surfaces. Check cylinder
head for warpage. Maximum warpage is .004" (.10 mm). Check minimum
cylinder head height and replace cylinder head (if necessary). See

CYLINDER HEAD table under ENGINE SPECIFICATIONS.

NOTE: DO NOT reuse antifreeze after replacing cylinder block,
cylinder head, head gasket, radiator and/or heater core.

Installation

1) Remove sealer from the two 3-mm holes and replace with new
sealer. See Fig. 6. Install gasket onto guide pins. Guide pins should
be located near bolt holes No. 12 and 20. See Fig. 7.

2) Install cylinder head onto cylinder block. Do not use any
type of sealant. Install head bolts and tighten by hand. Tighten
cylinder head bolts in sequence (4 steps) to specification. See Fig. 7
. See TORQUE SPECIFICATIONS.

Fig. 6: Sealing Cylinder Head 3-mm Holes
Courtesy of Volkswagen United States, Inc.

Fig. 7: Cylinder Head Bolts Tightening Sequence
Courtesy of Volkswagen United States, Inc.

CRANKSHAFT OIL SEAL

Removal
Install 8-mm bolt in belt tensioner hole and remove accessory
drive belt. See Fig. 2. Remove vibration damper. Loosen inner section
of Oil Seal Extractor (3203) about 3 turns (4 mm) and lock in position
with knurled screw. Turn inner section of oil seal extractor until
seal is removed.

Installation
Place Guide Sleeve (3266/1) on crankshaft. Push oil seal over
guide sleeve. Using Oil Seal Installer (3266) and vibration damper
bolt, press oil seal in completely. See Fig. 8. Reverse removal
procedure to complete installation.