03 Jetta 2.0 40k service

[The Critic]

Have a '03 Jetta 2.0 (AVH) 5MT in the shop today w/41k. Needs a 40k service.

I'm assuming:

- Oil/Filter Change: Valvoline 5W30 SM & Bosch Premium Filter
- Spark Plugs: Autolite Double Platinum APP3923
- Engine Air Filter: Fram
- Cabin Air Filter: Fram
- Replace Brake Fluid: Valvoline SynPower DOT3/DOT4

Did the oil change already, parts store is on the way with the plugs, engine air, and cabin air filter. Will do the brake fluid maybe next week? Am I missing anything VW experts?

Thanks.

 

[HondaMan]

Mike,

What plugs are in there presently? You know me, I would stick with the OE plugs.

Also, don't know if at 40k you would pull the plugs, BUT it is an older car... four years ... I would in fact change the plugs ... so... ignore this paragraph

 

[The Critic]

VW manual says to replace the plugs, engine air filter, replace the oil and filter, and do a brake inspection/tire rotation.

Cabin Air Filter is every 2-yr/20k, brake fluid (DOT4) is every 2 years regardless of mileage.

OE plugs are NGK Double Platinums that run $12/plug. At school right now and its the only "operable" car in the shop, so can't run to the dealer for the OE plugs. The teacher didn't know that car even needs plugs, so we just have to order from CSK which delivers.

 

[wavinwayne]

Quote:

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...Am I missing anything VW experts?

Thanks.

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No, other than visually inspecting everything, you've got it pretty much covered. I can't believe you're not using a VW 502.00 oil, though. J/K

 

[HondaMan]

Do you have Hi/Low / Oreilly's in Cali? They sell NGK. Delivery is always nice.

Wish I was in shop class

 

[huffmuds9320]

Everything on the to do list looks good. My Jetta has that same engine. You can ask the auto parts store like Kragen to order it for you. Yes I would recommend OEM or the equivalent plugs in this case NGKs. When you remove the spark plug boot, you don't have to use the OEM tool to remove it. I bought this boot puller at Autozone and it works great.

Wouldn't be a bad idea to check the manual transmission fluid level. You just open the fill plug and feel if its at the top of the hole. Much easier to work on than the automatics.

When you replace the cabin air filter, I find it easier to remove the whole plastic piece that runs on the bottom of th windshield.

Air filter. Optional step, I remove the air box assembly and the tube (coming into air box) to clean out the snow screen (looks like a net) too. Perhaps clean the throttle body if you like.

Good that you rotate the tires too. Don't forget to check the tire pressure. I run 32psi front 30psi rear, I find the tag on the gas door a little soft (26psi front/rear half load).

Conventional motor oil in a VW 2.0L engine? Does it consume oil?

Maybe the next 40k service you can change the fuel filter. Very easy to change.

Have fun with the maintenance. Let us know how it all goes.

 

[Tosh]

Quote:

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OE plugs are NGK Double Platinums that run $12/plug. At school right now and its the only "operable" car in the shop, so can't run to the dealer for the OE plugs. The teacher didn't know that car even needs plugs, so we just have to order from CSK which delivers.

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Then clean and re-gap the old plugs for now. (and take pics for us)

 

[The Critic]

Well, the Jetta is back on the road tonight with fresh oil and filter, plugs, engine air filter, cabin air filter, and fuel filter. Tires were rotated and checked for wear, pressure was set to 30F/41R (“loaded” pressure), and brakes were also inspected. The brake fluid change will have to wait as we ran out of time.

I did the last oil change on this car, and that was about 7000 miles ago using the same Valvoline 5W30 and Bosch Premium Filter. I don’t own this car, but the owner does not mention any significant oil consumption either. I know the person checks the oil on a regular basis though.

The fuel filter was indeed quite easy to change. It uses clips that push down, so no conventional fuel line removal tools are needed. Of course, the typical fuel filter mess was inevitable despite efforts to remove the fuel pump fuse and run the engine dry beforehand.

The plugs were a bit difficult to replace. Some injector wiring had to be removed to access the ones on cylinders two and three. We used Autolite Double Platinum plugs from Kragen. With shop discount, it was around $3.50/plug, much less than the $12/plug (if not more) price for the OE NGK Double Platinums. The Autolite plugs also had an additional $1.25/plug mail-in rebate, dropping the final price to about $2.25/plug. I must say, the pricey OE plugs looked very good when removed at 41k miles. Both platinum pads were still present, only a small amount of ash and the tips looked good. The plugs could’ve been regapped and reused, but the price of new plugs made replacement a no brainer.

MT lube is about $30/L for the low-viscosity OE fluid. Contrary to some internet rumors, the fluid is not synthetic 75W90. A test on TDIClub showed the fluid to have a viscosity of about 6.3 at 100C. It’s possible that early transmissions of the same type used 75W90 and the later models used the low-viscosity fluid, but I do not know that for certain and am unwilling to take the risk.

Finally, here were the parts that we used:

Oil Change- Valvoline 5W30/Bosch Premium Filter
Spark Plugs- Autolite Double Platinum APP3923
Air Filter- Fram
Fuel Filter- Fram
Cabin Air Filter- Generic

 

[Tosh]

Quote:

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Tires were rotated and checked for wear, pressure was set to 30F/41R (“loaded” pressure),

The plugs could’ve been regapped and reused, but the price of new plugs made replacement a no brainer.

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Those tire pressures don't sound right to me, as far as F/R difference. 30F/41R? How often is this Jetta fully loaded? Sounds like a recipe for funny handling.

I also find it hard to believe that VW intended for their nice OEM platinum plugs to be replaced so early. And then not using OEM? Maybe I'm just superstitious, but I thought replacing plugs with the exact replacement was the 'no brainer.'

 

[huffmuds9320]

The tire pressure sticker on the gas door on my 02 VW Jetta list the same thing. This is for the 195/65R/15 stock tires. They do have other tire listed as well for 16 and 17 inch tires. My tag says 26psi front/rear for half load and 30F/41R for full load. I know later on VW changed it to 30F/28R for half load and 32F/41R for full load. I run 32F/30R and it works good.

 

[HondaMan]

Tosh,

You are right on about the plugs. I do not believe that those Autolites will go 40k ....

BTW ... as an FYI to all, most dual electrode plugs are NOT to be gapped. NGKs and Bosch (German ones) that are dual state that they are not to be gapped.

Since the Autolites are more generic in nature, I'm sure they expect that they will perhaps have to be gapped.

So the OE plugs where almost 4 years old and looked good .. I believe it.

Mike, when they bring in a car to be serviced, does the owner have to pay? Or does the school pick up the tab so you guys can learn? i.e. I wonder who makes the call on trying to 'save vs. spend'?

 

[huffmuds9320]

The stock plugs are NGK single prong laser platinum (double platinum?). Drive by wire throttle 2.0L engines use NGK laser platinum. The non drive by wire 2.0L uses 3 prong NGK copper. What I find odd is they use NGK made in Japan plugs rather than German Bosch plugs.

Part number for 99-03 VW 2.0L engine if you are interested.
2.0L engine
AEG 2.0L (non drive by wire) NGK BKUR 6 ET-10 / VW 101-000-033-AA
AVH, AZG 2.0L (drive by wire) NGK PZF R5D-1 / VW 101-000-062-AB

2.0L 0.90-1.10mm (0.035-0.043 in.)

 

[The Critic]

Quote:

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I do not believe that those Autolites will go 40k ....

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The $2 copper plugs will go 30k in just about any engine. I see no reason why the double platinums will not last 40k miles in a healthy engine. Autolite backs the plugs with a five-year, unlimited mileage guarantee when they are used in the recommended application, which I am. They also advertise a 100k mile durability promise.

Quote:

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BTW ... as an FYI to all, most dual electrode plugs are NOT to be gapped. NGKs and Bosch (German ones) that are dual state that they are not to be gapped.

Since the Autolites are more generic in nature, I'm sure they expect that they will perhaps have to be gapped.

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Gapping plugs are really a practice of the past. I cannot think of a single application specific plug that needs to be gapped...all of them are ready to be installed right out of the box. Of course, my auto instructor still checked the gap before installing them because he's old school; I hope he didn't mess anything up.

Quote:

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Mike, when they bring in a car to be serviced, does the owner have to pay? Or does the school pick up the tab so you guys can learn? i.e. I wonder who makes the call on trying to 'save vs. spend'?

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School only picks up the tab on the infamous "shop supplies," such as towels, anti-seize, brake cleaner, etc. Usually it's only students who bring their cars in and work on them. The Jetta belonged to our auto instructor's daughter.

Quote:

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The stock plugs are NGK single prong laser platinum (double platinum?). Drive by wire throttle 2.0L engines use NGK laser platinum. The non drive by wire 2.0L uses 3 prong NGK copper. What I find odd is they use NGK made in Japan plugs rather than German Bosch plugs.

Part number for 99-03 VW 2.0L engine if you are interested.
2.0L engine
AEG 2.0L (non drive by wire) NGK BKUR 6 ET-10 / VW 101-000-033-AA
AVH, AZG 2.0L (drive by wire) NGK PZF R5D-1 / VW 101-000-062-AB

2.0L 0.90-1.10mm (0.035-0.043 in.)

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The ones that came out of the 03 Jetta 2.0 were the PZFR5D-1 as the 2.0 engine of that model year was DBW.