Maintenance (A4 Platform): Removal & Installation Volkswagen Jetta IV

Initial Installation of engine compartment cover (sound insulation) (R32)

Note. Engine compartment cover is not installed at factory and must be installed before delivery inspection. Inside front wheel house liner, 3 additional holes must be drilled. Engine compartment cover, fastening materials, as well as assembly instructions with drilling templates are found inside vehicle.

Necessary material

1. 4 spring nuts with self-tapping screws (anodized) for side engine compartment cover.
2. 12 spring nuts with self-tapping screws (black) for bumper cover
3. 9 spring nuts with self-tapping screws (black) for engine compartment cover outer edges

Removing

1. Remove both front wheels.

Note. Following illustration shows left wheel house liner. Installation of right wheel house liner is similar.

1. Cut out two drilling templates.

Scheme 112

1. Attach and align drilling template - 2 - to wheel house liner - 1 - and drill 3 holes - arrows -.
2. Drill holes using a 6 mm drill bit.

Scheme 113

1. Set spring nuts on indicated areas.

Installing

1. Rest front edge of engine compartment cover - arrow A - on bumper cover - 1 - and push in. Afterwards, push engine compartment cover up and have a second person hold it.

Note. Front edge of engine compartment cover - arrow A - must rest on bumper cover - 1 -. At outer reaches - arrow B - engine compartment cover must rest on bumper cover.

1. Install screw - arrow A - on respective side and tighten to 1.5 Nm.
2. Install screws at front - arrow B - then at sides - arrow C - and tighten to 1.5 Nm.
3. Install screws - arrow D - at wheel house liners and tighten to 1.5 Nm.

1. Install front wheels and tighten to specified tightening torque.

Scheme 114

1. The type plate - arrow - is found on the right strut tower.
2. Vehicles for certain countries have no type plate.

Break-down set, replace tire sealant (when shelf-life has expired)

Golf R32

Scheme 115

The tire sealant is located in the luggage compartment - 1 -.

1. Verify the expiration date.

The expiration date is printed on the tire sealant - arrow -.

1. Replace the tire sealant when it is more than 3 years old.

Note. If the tire sealant was already used once, it must be replaced. Observe waste disposal regulations!

Spark plugs, replace

Special tools, testers and auxiliary items required

Scheme 116

1. Spark plug wrench VAS 3122B

Scheme 117

1. Seal puller T10018

Scheme 118

1. Removal/Installation tool T10029

1. Puller T10095

1. Torque wrench V.A.G 1331/ (5 - 50 Nm)

Dust and pollen filter, replace filter element

Filter is located on right side in plenum chamber under cover.

Perform the following work sequence

Removing

Scheme 119

1. Remove upward the rubber seal - 1 - on the right of the plenum chamber cover to center of the vehicle.
2. Remove four screws - 2 - and remove the plenum chamber cover.

Scheme 120

1. Press the latches - A - of the filter housing in direction of - arrow - and remove filter element with frame upward.
2. Remove filter from the frame.

Note. Observe waste disposal regulations!

Installing

Scheme 121

1. Insert the left and right frame edges into the first fins of the new filter element - arrows -.

Scheme 122

1. Insert the frame into the appropriate recesses of the filter housing and latches - 1 - and secure the frame with filter element by pushing down.

1. Install the plenum chamber cover and fasten with 4 screws - 2 -.
2. Press on rubber seal - 1 -.

Air cleaner, clean housing and replace filter element

Note. Depending on vehicle equipment, there is a screen built into the area of the intake canal. This screen prevents snow and ice from entering the air filter housing and clogging the air filter during winter months. If dirty, the screen should be blown clean with pressurized air.