Volkswagen Jetta 1999 2000, Golf 1999 2000 User Manual

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
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.
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