Volkswagen 1.8L Turbo Engine Service Repair Manual

2000-02 ENGINES 1.8L 4-Cylinder Turbo 5-Valve ENGINE IDENTIFICATION Engine identification number is stamped on a machined pad on front of engine block, below cylinder head, where engine and transaxle mate together. See Fig. 1 . In addition there is a sticker on the valve with engine code and engine serial number. Engine code is also included on the vehicle data plate. ENGINE CODES 1.8L TURBO NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES article in the GENERAL INFORMATION. Model Engine Code 2000-01 Golf AWD & AWW GTI AWD & AWW Jetta AWD & AWW 2002 Beetle AWP GTI AWP Jetta AWP 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:33 Page 1 © 2004 Mitchell Repair Information Company, LLC.

Fig. 1: Locating Engine Identification Number Courtesy of VOLKSWAGEN UNITED STATES, INC. PROGRAMMING After any repair which required that the battery be disconnected, the following should be performed. Refer to owners manual for additional information. 1. Ensure ignition switch is in OFF position. Reconnect battery positive cable first then connect the negative ground strap. 2. After connecting battery, enter anti-theft code for radio (if equipped). 3. Fully close all power windows, operate each window door switch in up position for at least one 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. 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 2 © 2004 Mitchell Repair Information Company, LLC.

second (windows closed) to activate "one touch" opening/closing function (if equipped). 4. Set clock to correct time. ADJUSTMENTS ACCELERATOR PEDAL For testing and matching engine electronics control module to throttle valve control module. See THROTTLE VALVE CONTROL MODULE (J338) in appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. VALVE CLEARANCE Engine is equipped with non-adjustable, non-serviceable hydraulic valve adjusters. Irregular valve adjuster noise during cranking is normal. If valve adjuster(s) are noisy under any other condition inspect valve adjusters. See HYDRAULIC VALVE ADJUSTERS . HYDRAULIC VALVE ADJUSTERS Checking 1. Start engine and run until cooling fan cycles at least once. Increase engine speed to 2500 RPM for 2 minutes or test drive vehicle and observe valve train noise. If valve train noise is still considered noisy, go to next step. 2. Turn engine off. Remove valve cover. Rotate crankshaft until camshaft lobes point upward on lifter being checked. Using a wooden or plastic wedge, push down on top of lifter. See Fig. 2 . Try inserting a .008" (.20 mm) feeler gauge between top of lifter and camshaft. If feeler gauge fits between top of lifter and camshaft, replace faulty lifter. NOTE: A drive by wire throttle system is used on this model vehicle. No throttle cable adjustment required. WARNING: ALWAYS release fuel pressure before disconnecting fuel injection related component. DO NOT allow fuel to contact engine or electrical components. CAUTION: DO NOT start engine for about 30 minutes after installing camshafts. Hydraulic valve lifters must bleed down or valves may strike pistons. Rotate crankshaft by hand 2 full revolutions before starting engine to ensure valves do not strike pistons. NOTE: Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular valve train noise is normal when starting engine. 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 3 © 2004 Mitchell Repair Information Company, LLC.

Fig. 2: Placement Of Wedge On Lifter (Push Down) Courtesy of VOLKSWAGEN UNITED STATES, INC. TROUBLESHOOTING To trouble shoot mechanical engine components, see appropriate table in TROUBLE SHOOTING article in GENERAL INFORMATION. REMOVAL & INSTALLATION CAUTION: 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 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 4 © 2004 Mitchell Repair Information Company, LLC.

FUEL PRESSURE RELEASE Remove fuel pump relay located in fuse/relay panel (behind left side of dash). Start engine, allow engine to run until it stops. Turn ignition off. Disconnect negative battery cable. Install fuel pump relay. Slight pressure may remain in system. Before disconnecting any fuel system line, cover connector with a clean shop towel. COOLING SYSTEM BLEEDING 1. Ensure coolant drain valve is closed and all hoses are secure. See Fig. 3 and Fig. 4 . For help in identifying components and component locations, refer to illustration. See Fig. 5 and Fig. 6 2. Fill expansion tank to proper level. Fill to Max mark on expansion tank (up to 2001 models) or to upper portion of shaded area on expansion tank (2002 models). Install expansion tank cap. See Fig. 7 and Fig. 8 . 3. Put heater controls in Off position. Start engine and raise engine speed to 2000 RPM for about 3 minutes. Ensure cooling fan cycles on and off. Return engine to idle. Check coolant level in expansion tank. With engine at normal operating temperature, coolant should be at the Max mark indicated on expansion tank. Once engine has completely cooled, coolant should be between Max and Low marks. Add coolant as necessary. disconnecting battery. 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. Place mating marks on other major assemblies before removal. 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 5 © 2004 Mitchell Repair Information Company, LLC.

Fig. 3: Draining Coolant From Radiator Courtesy of VOLKSWAGEN UNITED STATES, INC. 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 6 © 2004 Mitchell Repair Information Company, LLC.

Fig. 4: Draining Coolant From Engine Block At Oil Cooler Courtesy of VOLKSWAGEN UNITED STATES, INC. 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 7 © 2004 Mitchell Repair Information Company, LLC.

Fig. 5: Identifying Cooling System Components & Hose Routing (AWD) Courtesy of VOLKSWAGEN UNITED STATES, INC. 2001 Volkswagen GTI GLS 1.8L 4-CYLINDER 5-VALVE TURBO 1 января 2005 г. 1:25:35 Page 9 © 2004 Mitchell Repair Information Company, LLC.

Volkswagen 1.8L Turbo Engine Service Repair Manual

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