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Volkswagen Jetta 2002 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Volkswagen Model: Jetta Year: 2002 Codes Chassis Code: A4 (MK4) 👋 Introduction Market Position Segment: Compact/Mid-size Sedan Target Audience: DIY enthusiasts, independent repair shops, Volkswagen owners Competitive Analysis Competitors: Honda Civic, Toyota Corolla, Ford Focus, Mazda3 Key Features Design Philosophy: German engineering, practical design, solid build quality Powertrain Options: Reliable and fuel-efficient inline-4 engines, optional potent VR6 Chassis Platform: A4 platform (MK4), shared with Golf and Beetle Manual Value: Essential for proper maintenance and repair, cost-saving for owners 📋 Manual Details Coverage Areas Primary Coverage: All mechanical and electrical systems Secondary Coverage: Bodywork, interior trim, maintenance schedules Page Count Total Pages: Approximately 1500+ Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: 2.0L ABA (SOHC), 1.8L AGU/AUM (DOHC Turbo), 2.8L AAA (VR6) Transmission: 5-speed Manual (02J), 4-speed Automatic (01M) Brakes: Front Ventilated Discs, Rear Solid Discs (ABS optional) Suspension: Front MacPherson struts, Rear Torsion Beam Axle (independent on VR6) Electrical: Engine management, body control modules (BCM), lighting, comfort systems, diagnostics (OBD-II) Climate Control: Manual and automatic climate control systems Fuel System: Fuel injection, fuel pump, fuel filter, evaporative emissions control Exhaust System: Catalytic converter, mufflers, oxygen sensors Cooling System: Radiator, water pump, thermostat, coolant types Steering: Power-assisted rack and pinion, steering angle sensor Body: Body panels, doors, hood, trunk, glass, seals Interior: Seats, dashboard, door panels, headliner, airbags Procedures Included Maintenance: Oil changes, filter replacements, spark plugs, timing belts (where applicable) Repair: Engine component repair, transmission overhaul, brake system servicing Disassembly Assembly: Detailed step-by-step guides for component removal and reinstallation Troubleshooting: Diagnostic procedures for common problems, fault code interpretation Installation: Component replacement and alignment procedures Wiring Diagrams: Complete electrical system schematics Technical Depth Depth: Comprehensive, covering from basic maintenance to complex overhauls and diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable Print Quality Resolution: High-resolution for clear diagrams and text Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine 1 Code: ABA Engine 1 Type: 2.0L SOHC Inline-4 Engine 1 Displacement Liters: 2.0 Engine 1 Horsepower Hp: 115 Engine 1 Torque Lb Ft: 122 Optional Engine 1 Engine 2 Code: AGU/AUM Engine 2 Type: 1.8L DOHC Turbocharged Inline-4 (16V) Engine 2 Displacement Liters: 1.8 Engine 2 Horsepower Hp: 150 Engine 2 Torque Lb Ft: 155 Optional Engine 2 Engine 3 Code: AAA Engine 3 Type: 2.8L SOHC VR6 (12V) Engine 3 Displacement Liters: 2.8 Engine 3 Horsepower Hp: 178 Engine 3 Torque Lb Ft: 184 Fuel System Fuel Delivery: Multi-point fuel injection (MPI) Recommended Fuel: 87 Octane (91 Octane recommended for Turbo/VR6 for optimal performance) Emissions Control: Catalytic converter, secondary air injection (on some models), evaporative emission control (EVAP) 🔧 Transmission Standard Type: 5-speed Manual (02J) Optional Type: 4-speed Automatic (01M) Features Clutch: Hydraulically actuated single dry plate clutch Automatic Features: Lock-up torque converter, sport/winter mode Fluid Specs Manual Fluid Type: VW G 052 171 A2 (or equivalent GL-4 75W-90) Automatic Fluid Type: ATF G 052 162 A1 (or equivalent JWS 3309 spec) 📐 Dimensions Exterior Length In: 174.7 Width In: 69.2 Height In: 57.5 Wheelbase In: 101.5 Weights Curb Weight Lbs Approx: 2900-3200 (depending on engine/options) Gross Vehicle Weight Rating Gvwr Lbs Approx: 4000-4200 Cargo Trunk Volume Cu Ft: 13.6 🛡️ Safety Features Ratings NHTSA Front Driver: 5-star NHTSA Front Passenger: 5-star IIHS Frontal Offset: Good Active Features ABS: Standard on most trims, optional on base models Traction Control: Optional (TCS) Passive Features Airbags Front: Driver and front passenger airbags Airbags Side: Optional front side-impact airbags Seatbelts: 3-point front and rear seatbelts with pretensioners and load limiters 💡 Technology Features Infotainment Radio Options: AM/FM stereo with CD player, optional Monsoon premium audio system Display: Digital clock and radio display Driver Assistance Cruise Control: Standard on most trims Headlights: Halogen reflector headlights, optional Xenon HID headlights Connectivity Power Windows: Standard Keyless Entry: Optional remote keyless entry 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles (12 months) or as indicated by oil service light Engine Oil Type: SAE 5W-40 Synthetic (VW 502 00/505 00 spec recommended) Oil Filter Part Number Example: VW 068 115 561 B Air Filter Replacement: Every 30,000 miles or as needed Cabin Filter Replacement: Every 20,000-30,000 miles Spark Plug Replacement 2.0L: Every 60,000 miles (standard ignition) Spark Plug Replacement 1.8T: Every 60,000 miles (platinum or iridium) Timing Belt Replacement 2.0L: Every 70,000-90,000 miles (interference engine) Timing Belt Replacement 1.8T: Every 70,000-90,000 miles (interference engine) Timing Belt Replacement Vr6: Not applicable (timing chain driven) Fluid Specifications Coolant Type: G 12 (Pink) Antifreeze/Coolant (VW TL 774-C spec) Coolant Capacity Qts: 8.0 Brake Fluid Type: DOT 4 Known Issues Ignition Coils: Coil-on-plug (COP) systems prone to failure Mass Airflow Sensor: Can become dirty or fail, affecting engine performance Oil Leaks:...
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Volkswagen Jetta 2002 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Volkswagen
Model:
Jetta
Year:
2002
Codes
Chassis Code:
A4 (MK4)
👋 Introduction
Market Position
Segment:
Compact/Mid-size Sedan
Target Audience:
DIY enthusiasts, independent repair shops, Volkswagen owners
Competitive Analysis
Competitors:
Honda Civic, Toyota Corolla, Ford Focus, Mazda3
Key Features
Design Philosophy:
German engineering, practical design, solid build quality
Powertrain Options:
Reliable and fuel-efficient inline-4 engines, optional potent VR6
Chassis Platform:
A4 platform (MK4), shared with Golf and Beetle
Manual Value:
Essential for proper maintenance and repair, cost-saving for owners
📋 Manual Details
Coverage Areas
Primary Coverage:
All mechanical and electrical systems
Secondary Coverage:
Bodywork, interior trim, maintenance schedules
Page Count
Total Pages:
Approximately 1500+
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
2.0L ABA (SOHC), 1.8L AGU/AUM (DOHC Turbo), 2.8L AAA (VR6)
Transmission:
5-speed Manual (02J), 4-speed Automatic (01M)
Brakes:
Front Ventilated Discs, Rear Solid Discs (ABS optional)
Suspension:
Front MacPherson struts, Rear Torsion Beam Axle (independent on VR6)
Electrical:
Engine management, body control modules (BCM), lighting, comfort systems, diagnostics (OBD-II)
Climate Control:
Manual and automatic climate control systems
Fuel System:
Fuel injection, fuel pump, fuel filter, evaporative emissions control
Exhaust System:
Catalytic converter, mufflers, oxygen sensors
Cooling System:
Radiator, water pump, thermostat, coolant types
Steering:
Power-assisted rack and pinion, steering angle sensor
Body:
Body panels, doors, hood, trunk, glass, seals
Interior:
Seats, dashboard, door panels, headliner, airbags
Procedures Included
Maintenance:
Oil changes, filter replacements, spark plugs, timing belts (where applicable)
Repair:
Engine component repair, transmission overhaul, brake system servicing
Disassembly Assembly:
Detailed step-by-step guides for component removal and reinstallation
Troubleshooting:
Diagnostic procedures for common problems, fault code interpretation
Installation:
Component replacement and alignment procedures
Wiring Diagrams:
Complete electrical system schematics
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to complex overhauls and diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable
Print Quality
Resolution:
High-resolution for clear diagrams and text
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
ABA
Engine 1 Type:
2.0L SOHC Inline-4
Engine 1 Displacement Liters:
2.0
Engine 1 Horsepower Hp:
115
Engine 1 Torque Lb Ft:
122
Optional Engine 1
Engine 2 Code:
AGU/AUM
Engine 2 Type:
1.8L DOHC Turbocharged Inline-4 (16V)
Engine 2 Displacement Liters:
1.8
Engine 2 Horsepower Hp:
150
Engine 2 Torque Lb Ft:
155
Optional Engine 2
Engine 3 Code:
AAA
Engine 3 Type:
2.8L SOHC VR6 (12V)
Engine 3 Displacement Liters:
2.8
Engine 3 Horsepower Hp:
178
Engine 3 Torque Lb Ft:
184
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Recommended Fuel:
87 Octane (91 Octane recommended for Turbo/VR6 for optimal performance)
Emissions Control:
Catalytic converter, secondary air injection (on some models), evaporative emission control (EVAP)
🔧 Transmission
Standard
Type:
5-speed Manual (02J)
Optional
Type:
4-speed Automatic (01M)
Features
Clutch:
Hydraulically actuated single dry plate clutch
Automatic Features:
Lock-up torque converter, sport/winter mode
Fluid Specs
Manual Fluid Type:
VW G 052 171 A2 (or equivalent GL-4 75W-90)
Automatic Fluid Type:
ATF G 052 162 A1 (or equivalent JWS 3309 spec)
📐 Dimensions
Exterior
Length In:
174.7
Width In:
69.2
Height In:
57.5
Wheelbase In:
101.5
Weights
Curb Weight Lbs Approx:
2900-3200 (depending on engine/options)
Gross Vehicle Weight Rating Gvwr Lbs Approx:
4000-4200
Cargo
Trunk Volume Cu Ft:
13.6
🛡️ Safety Features
Ratings
NHTSA Front Driver:
5-star
NHTSA Front Passenger:
5-star
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard on most trims, optional on base models
Traction Control:
Optional (TCS)
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional front side-impact airbags
Seatbelts:
3-point front and rear seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Radio Options:
AM/FM stereo with CD player, optional Monsoon premium audio system
Display:
Digital clock and radio display
Driver Assistance
Cruise Control:
Standard on most trims
Headlights:
Halogen reflector headlights, optional Xenon HID headlights
Connectivity
Power Windows:
Standard
Keyless Entry:
Optional remote keyless entry
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (12 months) or as indicated by oil service light
Engine Oil Type:
SAE 5W-40 Synthetic (VW 502 00/505 00 spec recommended)
Oil Filter Part Number Example:
VW 068 115 561 B
Air Filter Replacement:
Every 30,000 miles or as needed
Cabin Filter Replacement:
Every 20,000-30,000 miles
Spark Plug Replacement 2.0L:
Every 60,000 miles (standard ignition)
Spark Plug Replacement 1.8T:
Every 60,000 miles (platinum or iridium)
Timing Belt Replacement 2.0L:
Every 70,000-90,000 miles (interference engine)
Timing Belt Replacement 1.8T:
Every 70,000-90,000 miles (interference engine)
Timing Belt Replacement Vr6:
Not applicable (timing chain driven)
Fluid Specifications
Coolant Type:
G 12 (Pink) Antifreeze/Coolant (VW TL 774-C spec)
Coolant Capacity Qts:
8.0
Brake Fluid Type:
DOT 4
Known Issues
Ignition Coils:
Coil-on-plug (COP) systems prone to failure
Mass Airflow Sensor:
Can become dirty or fail, affecting engine performance
Oil Leaks:
Valve cover gasket, oil pan gasket, and oil filter housing seals can leak
Suspension Components:
Worn control arm bushings and ball joints can cause steering and ride issues
ABS Sensors:
Wheel speed sensors can fail, triggering ABS/ESP warning lights
Climate Control Actuators:
Blend door actuators can fail, causing temperature regulation issues
📚 Vehicle History
Brand Heritage
Volkswagen History:
Founded in Germany in 1937, known for durable and accessible vehicles like the Beetle and Golf.
Model Evolution
Jetta Heritage:
Introduced in 1979 as a sedan version of the Golf, becoming a popular compact sedan worldwide.
Mk4 Generation:
The 2002 Jetta is part of the fourth generation (MK4) Jetta, produced from 1999 to 2005.
Production
Manufacturing Location:
Mexico (Puebla), Germany, South Africa
Sales Peak Year Approx:
Early 2000s
🏆 Awards & Recognition
Recognitions
Safety Award 2002:
IIHS Top Safety Pick (for frontal offset crashworthiness)
Ratings
Consumer Reports Rating Approx:
Average to Above Average (depending on specific model year and engine)
Certifications
Emissions Certification:
Meets ULEV (Ultra-Low Emission Vehicle) standards in California and other states
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