Removal (GTI & Jetta - AAA Engine)
1) Obtain radio security code. Turn ignition off and wait for
20 seconds. Disconnect negative battery cable. Drain cooling system.
Disconnect front exhaust pipe from catalytic converter.
2) Install 8-mm bolt in belt tensioner hole and remove drive
belt. See Fig. 2. Remove ignition cable guide. Disconnect front and
rear motor mounts. Attach Engine Sling (2024A) to engine. See Fig. 3.
3) Lift engine enough to access water pump. Secure pulley
using Spanner Wrench (VAG 1590). Remove water pump bolts. Push engine
toward left side and remove water pump.
Installation
When installing motor mounts, ensure recess on engine bracket
fits into mounting tab of bonded rubber bushing. Hand tighten motor
mount bolts and light rock engine to ensure motor mounts are fully
seated. To complete installation, reverse removal procedure.
Removal & Installation (Golf & Jetta - AFP Engine)
1) Obtain radio security code. Turn ignition off and wait for
20 seconds. Disconnect negative battery cable. Drain cooling system.
2) Remove accessory belt. Remove pulley retaining bolts and
pulley from Coolant pump. Remove coolant pump bolts and coolant pump
from engine block.
3) To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS.
OIL PAN
Removal & Installation
1) Remove center, left and right damping pans. Drain oil.
Remove oil pan bolts. Remove oil pan using a rubber hammer if
necessary. Remove sealant residue from cylinder block and oil pan.
Ensure surfaces are free from grease and oil.
2) To install, apply 2-3 mm thick silicone bead around
sealing surface of oil pan. Immediately install oil pan and lightly
tighten all bolts. Ensure oil pan is flush with cylinder block.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedures. Allow sealer to dry 30
minutes before installing engine oil.
OVERHAUL
CYLINDER HEAD
Cylinder Head
Clean all gasket mating surfaces. Check cylinder head for
warpage. Ensure warpage does not exceed .0039" (.100 mm).
Valve Stem Oil Seals
With valve springs removed, remove oil seals using Valve Seal
Remover (3047A). To install new oil seal, slide plastic sleeve over
valve stem. Lubricate new oil seal. Using Valve Seal Installer (3129),
push oil seal on valve guide.
Valve Guides
1) Check valve-to-guide clearance specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. If valve guides have
previously been replaced, replace cylinder head.
2) To replace valve guide, press guide out from camshaft
side. Lubricate guide and press in cold cylinder head (from camshaft
side) until shoulder makes contact. DO NOT exceed one ton pressure.
Ream guides to proper valve-to-guide clearance. See CYLINDER HEAD
table under ENGINE SPECIFICATIONS.
