VW 1.8 awd_aww_awp [2000-2002] repair and service.pdf

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2001 Volkswagen GTI GLS
1.8L 4-CYLINDER 5-VALVE TURBO
2000-02 ENGINES
1.8L 4-Cylinder Turbo 5-Valve
ENGINE IDENTIFICATION
NOTE:
For engine repair procedures not covered in this article, see
ENGINE
OVERHAUL PROCEDURES
article in the GENERAL INFORMATION.
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
Model
2000-01
Golf
GTI
Jetta
2002
Beetle
GTI
Jetta
Engine Code
AWD & AWW
AWD & AWW
AWD & AWW
AWP
AWP
AWP
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2005
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Page 1
© 2004 Mitchell Repair Information Company, LLC.
2001 Volkswagen GTI GLS
1.8L 4-CYLINDER 5-VALVE TURBO
Fig. 1: Locating Engine Identification Number
Courtesy of VOLKSWAGEN UNITED STATES, INC.
PROGRAMMING
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.
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
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© 2004 Mitchell Repair Information Company, LLC.
2001 Volkswagen GTI GLS
1.8L 4-CYLINDER 5-VALVE TURBO
second (windows closed) to activate "one touch" opening/closing function (if equipped).
4. Set clock to correct time.
ADJUSTMENTS
ACCELERATOR PEDAL
NOTE:
A drive by wire throttle system is used on this model vehicle. No throttle
cable adjustment required.
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
WARNING:
ALWAYS release fuel pressure before disconnecting fuel injection related
component. DO NOT allow fuel to contact engine or electrical components.
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.
Valve lifters are not repairable or adjustable. Replace faulty lifters. Irregular
valve train noise is normal when starting engine.
CAUTION:
NOTE:
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.
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2005
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© 2004 Mitchell Repair Information Company, LLC.
2001 Volkswagen GTI GLS
1.8L 4-CYLINDER 5-VALVE TURBO
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
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© 2004 Mitchell Repair Information Company, LLC.
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2005
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2001 Volkswagen GTI GLS
1.8L 4-CYLINDER 5-VALVE TURBO
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.
For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Place mating marks on other major assemblies
before removal.
NOTE:
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.
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© 2004 Mitchell Repair Information Company, LLC.

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