VW Jetta 2005, Bora 2006 4-cylinder Injection engine (1.6 l engine, direct injection) BLF - Workshop Manual

1.1 Engine number......Page 7
1.2 Engine data......Page 8
1 Removing and installing engine......Page 9
1.1 Removing engine......Page 10
1.2 Securing engine to engine and gearbox support -VAS 6095-......Page 20
1.3 Installing engine......Page 22
1.4.2 Adjusting assembly mounting......Page 26
1.5 Assembly mountings......Page 28
1 Dismantling and assembling engine......Page 30
1.1 Overview......Page 31
1.2 Belt drive - Assembly overview......Page 32
1.3 Chain drive - Assembly overview......Page 33
1.4 Removing and installing poly V-belt......Page 35
1.5 Removing and installing control housing......Page 37
2.1 Flywheel end - Assembly overview......Page 42
2.2 Renewing crankshaft oil seal - belt pulley end......Page 44
2.3 Tighten bolt for poly V-belt sprocket - crankshaft......Page 46
2.4 Renewing crankshaft sealing flange -flywheel end-......Page 49
2.5 Removing and installing flywheel......Page 56
3.1 Crankshaft dimensions......Page 58
4.1 Pistons and conrods - Assembly overview......Page 59
4.2 Check piston......Page 60
4.3 Piston and cylinder dimensions......Page 61
1 Cylinder head......Page 62
1.1 Cylinder head - Assembly overview......Page 63
1.2 Removing and installing camshaft housing......Page 65
1.2.1 Remove camshaft housing......Page 66
1.2.2 Installing camshaft housing......Page 67
1.3 Removing and installing cylinder head......Page 69
1.3.1 Remove cylinder head......Page 70
1.3.2 Install cylinder head......Page 71
1.4 Checking valve timing......Page 73
1.5 Adjusting valve timing......Page 75
1.6 Check compression pressures......Page 80
2.1 Valve gear - Assembly overview......Page 82
2.2 Checking camshaft axial clearance......Page 84
2.3 Reworking valve seats......Page 85
2.4 Checking valve guides......Page 86
2.5 Renewing valve stem seals......Page 87
1.1 Engine oil......Page 89
1.2 Parts of the lubrication system - Assembly overview......Page 90
1.3 Oil cooler - Assembly overview......Page 92
1.4 Removing and installing oil sump......Page 93
1.5 Removing and installing oil pump......Page 95
1.6 Removing and installing oil cooler......Page 98
1.7 Checking oil pressure and oil pressure switch......Page 100
1 Removing and installing parts of cooling system......Page 102
1.1 Parts of cooling system - body side - Assembly overview......Page 103
1.2 Parts of cooling system engine side (thermostat side) - Assembly overview......Page 104
1.4 Coolant hose schematic diagram......Page 105
1.4.1 Models without auxiliary heating......Page 106
1.4.2 Models with auxiliary heater......Page 107
1.5 Draining and filling coolant......Page 108
1.6 Removing and installing radiator fan -V7- and radiator fan 2 -V177-......Page 111
1.7 Removing and installing radiator......Page 112
1.8 Removing and installing coolant pump......Page 114
1.9 Removing and installing thermostat......Page 116
1.10 Check cooling system for leaks:......Page 119
1.2 Rules for cleanliness......Page 121
1.3 Fuel tank - Assembly overview......Page 122
1.4.1 Emptying fuel tank if it is more than 3/4 full......Page 124
1.4.2 Emptying fuel tank if it is less than 3/4 full......Page 125
1.5 Removing and installing fuel tank......Page 126
1.7 Removing and installing fuel filter......Page 129
2.1 Safety precautions when working on fuel supply system......Page 132
2.4 Removing and installing fuel delivery unit......Page 133
2.5 Removing and installing fuel gauge sender -G-......Page 135
2.6 Checking fuel pump......Page 136
2.6.1 Checking function and voltage supply......Page 138
2.6.2 Checking fuel pressure......Page 139
2.6.3 Checking holding pressure......Page 141
2.6.4 Checking delivery rate......Page 142
2.6.5 Checking current consumption......Page 144
2.7 Removing and installing high-pressure pump......Page 145
3.1 Function of EPC system......Page 150
3.3 Removing and installing accelerator pedal module......Page 151
4.1 Functional check......Page 153
4.3 Checking fuel tank breather......Page 154
1.1 General notes on injection......Page 156
1.2 Safety precautions......Page 157
1.3 Rules for cleanliness......Page 158
1.4 Fitting locations overview......Page 159
1.6 Air cleaner/engine cover - Assembly overview......Page 166
1.7 Removing and installing engine cover with air cleaner......Page 167
1.8 Intake manifold - Assembly overview......Page 168
1.9 Removing and installing intake manifold......Page 170
1.10 Fuel rail with injectors - Assembly overview......Page 173
1.11 Removing and installing fuel rail......Page 174
1.12 Removing and installing injectors......Page 176
1.13 Cleaning throttle valve module -J338-......Page 179
2.1 Check vacuum reservoir in intake manifold for leaks......Page 181
2.3 Checking intake air preheating......Page 182
3.1 Reading and erasing engine control unit fault memory......Page 184
3.2.1 Removing and installing engine control unit without theft protection......Page 185
3.2.2 Removing and installing anti-theft engine control unit......Page 186
1 Removing and installing parts of exhaust system......Page 189
1.1 Catalytic converters and attachments - Assembly overview......Page 190
1.3 Removing and installing exhaust manifold......Page 192
1.4 Removing and installing pre-catalytic converter with exhaust manifold......Page 194
1.5 Connecting and disconnecting front and rear silencers......Page 196
1.6 Aligning exhaust system free of stress......Page 198
2.1 Assembly overview - Exhaust gas recirculation system......Page 200
2.2 Removing and installing exhaust gas recirculation valve -N18-......Page 201
1.1 Safety precautions......Page 203
1.3 Removing and installing ignition coils with output stage......Page 204
1.4 Spark plug test data......Page 205