This DIY repair manual by Chilton, covers U.S. and Canadian models of 1999-2005 VW Golf, Jetta and GTI with 1.8L turbo and 2.0L gasoline engines, and 1.9L turbocharged diesel engine. Note: This manual does not include info for models with the VR6 engine, 5-cylinder engine, 2004 and later TDI-PD diesels, Golf R32 AWD models, Cabrio (convertible) models or early 1999 models built upon A3 platforms.
Book Excerpt: 1999-2005 VW Golf, Jetta, GTI Repair Manual GENERAL ENGINE OVERHAUL PROCEDURES

ENGINE BLOCK | CLEANING
(Refer to illustrations 15.3, 15.4a, 15.4b, 15.4c and 15.8)

1. Remove the main bearing caps and separate the bearing inserts from the caps and the engine block. Tag the bearings, indicating which cylinder they were removed from and whether they were in the cap or the block, then set them aside.
2. Using a gasket scraper, remove all traces of gasket material from the engine block. Be very careful not to nick or gouge the gasket sealing surfaces.
3. Remove all of the covers and threaded oil gallery plugs from the block. The plugs are usually very tight - they may have to be drilled out and the holes retapped. Use new plugs when the engine is reassembled. Where applicable, it will also be necessary to remove the oil spray jets from the engine block (see illustration).
4. Remove the oil filter adapter from the engine. Disassemble the components from the adapter housing and inspect them for wear and damage. Look for nicks and scoring especially on the pressure relief valve piston (see illustrations). Clean the components and the oil passages in the housing thoroughly with solvent, then dry them with compressed air. If in doubt about the condition of the adapter housing and its components, replace it with a new one.
5. If the engine is extremely dirty, it should be taken to an automotive machine shop to be cleaned.
6. After the block is returned, clean all oil holes and oil galleries one more time. Brushes specifically designed for this purpose are available at most auto parts stores. Flush the passages with warm water until the water runs clear, dry the block thoroughly and wipe all machined surfaces with a light rust preventive oil. If you have access to compressed air, use it to speed the drying process and blow out all the oil holes and galleries.

AUTOMATIC TRANSAXLE

DRIVE FLANGE OIL SEAL | REPLACEMENT
(Refer to illustrations 6.3 and 6.7)

1. The drive flange oil seals are located at the sides of the transaxle, where the driveaxles are attached. If leakage at the seal is suspected, raise the vehicle and support it securely on jackstands. If a seal is leaking, lubricant will be found on the sides of the transaxle.
2. Refer to Chapter 8 and unbolt the driveaxle from the drive flange. Position the driveaxle out of the way and support it with a piece of wire.
3. Place a drain pan under the transaxle and remove the drive flange:
1. On 4-speed transaxles (01M), pry the cap from the center of the flange, and then remove the snap ring.
2. On 5-speed transaxles (09A), remove the bolt securing the drive flange shaft and then pull the drive flange off the transaxle. Remove the drive flange using a puller; if necessary (see illustration).
4. Pry the oil seal out of the transaxle bore with a seal removal tool or a large screwdriver.
5. Pack the open side of the new seal with multi-purpose grease, and then drive it into its bore using a seal installation tool or a large socket with an outside diameter slightly smaller than that of the seal. Make sure the seal enters the bore squarely, and is driven in until it is completely seated.

Subject: 1999, 2000, 2001, 2002, 2003, 2004, 2005 Volkswagen Golf, Jetta, GTI service, maintenance, repair. ISBN-10: 1563927187 | ISBN-13: 9781563927188 | Chilton 70403