VW Jetta 2005, Bora 2006, Golf Variant 2007 4-cylinder diesel engine with unit injector BKC BLS BRM BXE - Workshop Manual

1.2 Engine data......Page 7
1.1 Removing engine......Page 8
1.2 Securing engine to assembly stand......Page 21
1.3 Installing engine......Page 22
1.4.1 Checking......Page 25
1.4.2 Adjusting assembly mounting......Page 26
1.5 Assembly mounting - Torque settings......Page 29
1 Dismantling and assembling engine......Page 30
1.1 Assembly overview......Page 31
1.2 Assembly overview - toothed belt drive......Page 32
1.3 Assembly overview - poly-V-belt drive......Page 33
1.4 Assembly overview - cylinder block......Page 34
1.5.1 Removing......Page 35
1.5.2 Installing......Page 36
2.1 Assembly overview - sealing flange and flywheel......Page 38
2.2 Renewing crankshaft oil seal (pulley end)......Page 39
2.2.2 Installing......Page 40
2.3.1 Removing......Page 41
2.3.2 Installing......Page 42
2.4 Renewing crankshaft sealing flange - flywheel end......Page 44
2.4.1 Pressing out sealing flange with sender wheel......Page 45
2.4.3 A - Fit assembling seal with sender wheel on assembly appliance -T10134-......Page 46
2.4.4 B - Attaching assembling tool -T10134- with sealing flange to crankshaft flange......Page 48
2.4.5 C - Bolting assembly tool -T10134- onto crankshaft flange......Page 49
2.4.7 E - Checking sender wheel installation position on crankshaft......Page 50
2.5 Removing and installing dual-mass flywheel......Page 51
2.5.1 Removing......Page 52
2.5.2 Installing......Page 53
3.1 Assembly overview - crankshaft......Page 54
3.4 Pulling needle bearing out of and driving into crankshaft......Page 55
4.1 Assembly overview - pistons and conrods......Page 58
4.2 Checking piston projection at TDC......Page 59
4.4 Piston rings, cylinder bore and piston installation position......Page 60
1 Cylinder head......Page 63
1.1 Assembly overview - cylinder head......Page 64
1.2 Removing and installing cylinder head cover......Page 67
1.3 Removing, installing and tensioning toothed belt......Page 68
1.3.1 Removing and installing toothed belt (on vehicles 05.05)......Page 69
1.3.2 Removing and installing toothed belt (on vehicles 06.05 )......Page 78
1.4 Removing and installing cylinder head......Page 85
1.4.1 Removing......Page 86
1.4.2 Installing......Page 88
1.5 Checking compression......Page 89
2 Valve gear......Page 92
2.1 Assembly overview - valve gear......Page 93
2.2 Checking axial clearance of camshaft......Page 94
2.5 Checking valve guides......Page 95
2.6.1 Removing......Page 96
2.6.2 Installing......Page 97
2.7.1 Removing......Page 98
2.7.2 Installing......Page 100
2.8 Removing and installing camshaft oil seal......Page 101
2.8.2 Installing......Page 102
1.3 Checking engine oil level......Page 103
2.1 Oil pump, oil sump - assembly overview, engine codes BKC, BLS, BXE......Page 104
2.2 Oil pump, oil sump - assembly overview, engine codes BRM......Page 106
2.3 Removing and installing sump......Page 107
2.3.1 Removing......Page 108
2.3.2 Installing......Page 109
2.4.1 Removing......Page 110
2.4.2 Installing......Page 111
3.1 Assembly overview - oil filter bracket and oil cooler......Page 112
3.2 Removing and installing oil filter bracket with oil cooler......Page 113
3.2.1 Removing......Page 114
3.2.2 Installing......Page 117
3.3 Checking oil pressure and oil pressure switch......Page 118
3.4 Assembly overview - oil supply line to turbocharger......Page 119
3.5.1 Removing......Page 120
3.5.2 Installing......Page 122
1 Parts of the cooling system......Page 123
1.1 Parts of cooling system - body side, engine codes BLS, BRM......Page 124
1.2 Parts of cooling system - body side, engine codes BKC, BXE......Page 125
1.3 Parts of cooling system - engine side, engine codes BLS, BRM......Page 126
1.4 Parts of cooling system - engine side, engine codes BKC, BXE......Page 129
1.5.1 Connection diagram, engine codes BKC, BXE......Page 131
1.5.2 Connection diagram, engine codes BLS, BRM......Page 132
1.6.1 Draining......Page 133
1.6.2 Filling......Page 135
1.7.1 Removing......Page 136
1.7.2 Installing......Page 137
1.8.1 Removing......Page 138
1.8.2 Installing......Page 139
1.9.1 Removing......Page 140
1.9.2 Installing......Page 141
1.10.1 Removing......Page 142
1.10.2 Installing......Page 143
1.11 Checking cooling system for leaks......Page 144
1.12 Checking oil cooler for leaks......Page 146
1 Safety precautions when working on fuel supply system......Page 148
2 Rules for cleanliness......Page 149
3 Fuel tank, models with front-wheel drive......Page 150
3.1 Assembly overview - fuel tank......Page 151
3.2.1 Emptying fuel tank if it is more than 3/4 full......Page 153
3.2.2 Emptying fuel tank if it is less than 3/4 full......Page 154
3.3 Removing and installing fuel tank......Page 155
3.4.1 Removing......Page 158
3.4.2 Installing......Page 159
3.6 Checking fuel pump......Page 160
3.6.1 Checking function and voltage supply......Page 161
3.6.2 Checking current consumption of fuel pump......Page 162
4.1 Assembly overview - fuel filter......Page 164
4.2.1 Removing......Page 165
4.3.1 Checking delivery pressure......Page 166
4.3.2 Checking for internal leaks......Page 169
4.4.1 Removing......Page 172
4.4.2 Installing......Page 174
5.1 Function of EPC system......Page 176
5.3 Removing and installing accelerator pedal module......Page 177
1.2 Rules for cleanliness......Page 179
2.1 Turbocharger - Assembly overview, engine codes BKC, BXE......Page 181
2.2 Removing and installing turbocharger, engine codes BKC, BXE......Page 183
2.2.1 Removing......Page 184
2.2.2 Installing......Page 188
2.3 Parts of charge air cooling - Assembly overview, engine codes BKC, BXE......Page 189
3.1 Turbocharger - Assembly overview, engine codes BLS (without diesel particulate filter), BRM......Page 191
3.2 Removing and installing turbocharger, engine codes BLS (without diesel particulate filter), BRM......Page 194
3.2.1 Removing......Page 195
3.2.2 Installing......Page 199
3.3 Turbocharger - Assembly overview, engine code BLS (with diesel particulate filter)......Page 201
3.4 Removing and installing turbocharger, engine code BLS (with diesel particulate filter)......Page 202
3.5 Parts of charge air cooling - Assembly overview, engine codes BLS, BRM......Page 204
4.1.1 Hose connections with connector couplings......Page 206
4.1.2 Hoses with spring washer......Page 207
5.1.2 Installing......Page 208
6 Checking charge air system for leaks......Page 210
7.1 Vehicles with engine codes BKC, BXE......Page 212
7.2 Vehicles with engine codes BLS, BRM......Page 213
1 Diesel direct injection system......Page 214
1.1 Safety precautions......Page 215
1.2 Rules for cleanliness......Page 216
1.3 Fitting locations overview......Page 217
1.4 Assembly overview - unit injector......Page 223
1.5.1 Removing......Page 225
1.5.2 Installing......Page 226
1.6.2 Installing......Page 228
1.7.1 Intake manifold - Assembly overview, engine codes BKC, BXE......Page 230
1.7.2 Intake manifold - Assembly overview, engine codes BLS, BRM......Page 231
1.8.1 Removing and installing intake manifold, engine codes BKC, BXE......Page 232
1.8.2 Removing and installing intake manifold, engine codes BLS, BRM......Page 237
1.9.2 Installing......Page 239
1.10 Dismantling and assembling intake pipe with with exhaust gas recirculation potentiometer -G212- and exhaust gas recirculation valve -N18-, engine codes BLS, BRM......Page 240
1.11.1 Removing......Page 241
1.11.2 Installing......Page 242
1.12 Assembly overview - air filter......Page 243
1.14 Connection diagram for solenoid valve block, engine codes BKC, BXE......Page 244
1.15.1 Removing......Page 245
1.17.1 Removing......Page 246
1.17.2 Installing......Page 248
2.1 Reading and clearing engine control unit fault memory......Page 249
2.2 Adapting functions and components......Page 250
2.3.2 Removing and installing anti-theft engine control unit......Page 251
1 Exhaust system......Page 254
1.1.1 Parts of exhaust system - Assembly overview, engine codes BKC, BXE......Page 256
1.1.2 Parts of exhaust system - Assembly overview, engine codes BLS (with catalytic converter), BRM......Page 257
1.1.3 Front exhaust pipe - Assembly overview, engine code BLS (with diesel particulate filter)......Page 258
1.1.4 Silencer - Assembly overview, engine code BLS (with diesel particulate filter)......Page 259
1.2.1 Removing and installing front exhaust pipe with catalytic converter, engine codes BKC, BXE......Page 260
1.2.2 Removing and installing front exhaust pipe with catalytic converter, engine codes BLS, BRM......Page 261
1.2.3 Removing and installing front exhaust pipe with diesel particulate filter, engine code BLS......Page 263
1.3 Connecting and disconnecting front and rear silencers......Page 265
1.4 Stress-free alignment of exhaust system......Page 266
2.1.1 Parts of exhaust gas recirculation - Assembly overview, engine codes BKC, BXE......Page 268
2.1.2 Parts of the exhaust gas recirculation - Assembly overview, engine codes BLS, BRM......Page 269
2.2 Parts of the exhaust gas recirculation cooler - Assembly overview, engine codes BLS, BRM......Page 271
2.3.1 Removing and installing exhaust gas recirculation cooler, engine codes BKC, BXE......Page 272
2.3.2 Removing and installing exhaust gas recirculation cooler, engine codes BLS, BRM......Page 277
2.4 Check mechanical exhaust gas recirculation valve, engine codes BKC, BXE......Page 278
1.1 Checking, removing and installing glow plugs......Page 280
1.1.2 Removing and installing ceramic glow plugs, checking......Page 281