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2002 Jetta TDI
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Discussion Starter #1
Doing the timing belt replacement on my 2002 Jetta TDI (ALH). I'm ready to install the new timing belt and supporting replacement parts. Checking out my passenger (right) side engine mount/ bracket determined it needs to be replaced (p/n VW# 038 199 207 h) threads are stripped. The starting threads are damaged; can't even start the bolt by hand.

I have no problem ordering a new replacement part (about $100); I am having difficulty understanding how to remove this engine mount/ bracket, so I can then install the new part. There does not seem to be enough room to wiggle to bracket out. Do I need to remove the back portion of the TB cover? If so do I need to remove the IP sprocket - is this doable?

I've read this engine mount bracket is an aluminum part and only has about three uses. I do have the Metalman TB kit with new bolts.

Any suggestions how to remove this mount/ bracket would be greatly appreciated. :bowdown
 

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If you lower the engine as much as it will comfortably go, you can twist it out...

If you're really not able to find the one spot in the puzzle that will let it slide out, you could remove the air intake tube to the turbo inlet (the one that comes from the flexible hose from the MAFs and goes around to the passenger side of the turbo), and then the lower engine mount / bracket should just slide out.

Have fun,

Yuri
 

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2002 Jetta TDI
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Discussion Starter #3
How Low Can an Engine Go

Using my Harbor Freight cheapy jack I was able to lower the engine about one inch and remove the old stripped engine mount bracket.

I was sweating it big time - the advise work great - thanks a million :eek:

Tomorrow the new bracket arrives - so I'll need to get my courage up to lower the engine again for the install.

I've begun a new level of respect for those who make a living as a mechanic.
 

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2002 Jetta TDI
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Discussion Starter #5
Already received the new mount bracket from MetalmanParts - ready to install.

I like the idea of repairing the bracket with helicoils - want to get the TB job done
so time is important went with the new part.

Might consider the helicoil repair, and see if someone is interested in buying
from me at reasonable price. Or simply purchase the helicoils if someone already
has repair capability.

Thanks :D
 

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2002 Jetta TDI
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Discussion Starter #7
TB Done - Engine Started - Time to Party

Timing belt replacement on the 2002 Jetta took longer than I expected - engine started I'm ready to party. :nana2:

Did a real quick TDI timing with the VCDS (will get a better measurement tomorrow after letting the engine warm up). Any feedback or advice is appreciated (see attached screen capture) - I plan to fine tune to the IP sprocket get closer to the blue line.

Glad I replaced the mount bracket - I did experience stripped threads on the engine mount when I re-installed the 13mm engine mount alignment plate. I was not able to torque this one bolt; ended using blue Locktite. Not sure how critical this bracket/ bolt is.
 

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The 13mm alignment bolts? They aren't holding anything up critical. The 18 mm engine mount mounts are really critical, if they fail your engine falls down and you won't be a happy camper.
 

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2002 Jetta TDI
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Discussion Starter #9
The 18mm bolts on the engine mount are new from Metalman TB kit - torqued at 74 ft-lbs no problem. I also was careful not to let the 18mm bolts support the engine while I torqued them. The engine mount is fully torqued with no problems. :eek:
 

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Discussion Starter #10
Advanced Timing After TB Job - Ready for Timing/ VCDS Adjustment.

Connected my new Ross-Tech VCDS to my 2002 Jetta and took the following TDI timing measurement - see attached screen shot from my PC.

My intial measurement with the new TB is advanced but in spec. When I come home from work tonight will adjust the IP sprocket slightly to get it closest to the middle, but maybe slightly advanced.

Used the "cloud" function to record the movements - seems like the timing is moving around (not stable). I had taken a TDI timing measurement prior to the TB replacement and had the same moving - possibly something other than the TB components (fuel injector/ IP?).

Any feedback on this before I adjust my timing is appreciated. :thumbsup
 

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It will move around a bit. Also, I would leave it where it is. A little advanced is fine as long as you're below the top line and as the belt ages it'll get a little retarded anyways.
 

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Discussion Starter #12
Sounds like a plan - I'll leave the timing as is and let time slowly retard it - this site is the best.

On this TB job I figure I saved $1000 or more doing it myself (local S. Cal VW dealer wanted $1400). More important is the learning - priceless.

Thanks for all the words of advice - and thanks in advance for the next projects I have planned - clean intake/ ERG, new struts, install engine splash guard previous owner thru away, and more than I can list here :D
 

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Lower Engine Mount Removal

If you lower the engine as much as it will comfortably go, you can twist it out...

If you're really not able to find the one spot in the puzzle that will let it slide out, you could remove the air intake tube to the turbo inlet (the one that comes from the flexible hose from the MAFs and goes around to the passenger side of the turbo), and then the lower engine mount / bracket should just slide out.

Have fun,

Yuri

We know this part is not removed for a Timing Belt job unless the engine is removed.
Is it possible to remove and install this part with the Timing Belt and Sprockets already in place??
Like if someone took it out after the old timing belt was removed and attempts to install it after the new belt and sprockets are in place??

Please explain. :confused:
 

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When my mount needed replacement I pulled the mount out of the way once I had the old belt and rollers off. Got sidetracked and put the new belt and rollers on then realized I forgot to install the mount. I had to remove the timing belt covers and jack the engine up and down until the mount was able to slip over the belt and between the rollers. It was a real pain to get the right spot where it went in but it did go and now I always make sure the mount is in position where all I have to do is slide it to bolt it up and not try to go over the new belt.
 

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Thank you for your input.
That is the situation I had in mind; where someone might have installed the belt and forgot to first put the engine support in position.

Did it go in from the bottom towards the firewall side, or from the top??

Thanks again.
 

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From the bottom... It will be MUCH easier if you remove the intake tube to the turbo... (2 bolts and a spring clamp)

Yuri
 

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From the bottom... It will be MUCH easier if you remove the intake tube to the turbo... (2 bolts and a spring clamp)

Yuri
Thanks Yuri.
I am not doing this work but had this discussion with a friend while replacing the crankshaft pulley bolts.
After reading your instructions I can visualize removing the turbo intake pipe, timing belt lower covers and even the small idle roller under the tensioner. Lowering the engine will create all the space needed after that.
I have to say that in the past I have broken the cooling fan while lowering the engine carelessly.

Thanks again to all of you.
 

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If you're considering removing the lower idler, then you're essentially re-doing the timing belt installation... (which means that you also need the lockdown and camshaft sprocket removal tools...)

In case you need expert help, keep in mind that there's a superb TDI specialist in Austin... www.runonbeer.com

All the best,

Yuri
 
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