VW 4-Cylinder Diesel Engine With Unit Injector Workshop Manual

VW 4-Cylinder Diesel Engine With Unit Injector Workshop Manual PDF free online

Diesel Engine is installed in the Volkswagen Jetta 2005 ➤, Bora 2006 ➤, Golf Variant 2007 ➤

  • Engine ID: BKC, BLS, BRM, BXE

List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 – Technical data
10 – Removing and installing engine
13 – Crankshaft group
15 – Cylinder head, valve gear
17 – Lubrication
19 – Cooling
20 – Fuel supply system
21 – Turbocharging/supercharging
23 – Mixture preparation – injection
26 – Exhaust system
28 – Glow plug system

CONTENTS

  • 00 – Technical data
    • Technical data
    • Engine number
    • Engine data
  • 10 – Removing and installing engine
    • Removing and installing engine
    • Removing engine
    • Securing engine to assembly stand
    • Installing engine
    • Checking and adjusting assembly mounting
    • Assembly mounting – Torque settings
  • 13 – Crankshaft group
    • Dismantling and assembling engine
    • Assembly overview
    • Assembly overview – toothed belt drive
    • Assembly overview – poly-V-belt drive
    • Assembly overview – cylinder block
    • Removing and installing poly-V-belt
    • Removing and installing sealing flange and flywheel
    • Assembly overview – sealing flange and flywheel
    • Renewing crankshaft oil seal (pulley end)
    • Removing and installing sealing flange – pulley end
    • Renewing crankshaft sealing flange – flywheel end
    • Removing and installing dual-mass flywheel
    • Crankshaft
    • Assembly overview – crankshaft
    • Crankshaft dimensions
    • Identification of upper crankshaft bearing
    • Pulling needle bearing out of and driving into crankshaft
    • Pistons and connecting rods
    • Assembly overview – pistons and conrods
    • Checking piston projection at TDC
    • Piston and cylinder dimensions
    • Piston rings, cylinder bore and piston installation position
  • 15 – Cylinder head, valve gear
    • Cylinder head
    • Assembly overview – cylinder head
    • Removing and installing cylinder head cover
    • Removing, installing and tensioning toothed belt
    • Removing and installing cylinder head
    • Checking compression
    • Valve gear
    • Assembly overview – valve gear
    • Checking axial clearance of camshaft
    • Seal bearing caps 1 and 5 contact surfaces
    • Valve dimensions
    • Checking valve guides
    • Renewing valve stem oil seals
    • Removing and installing camshaft
    • Removing and installing camshaft oil seal
  • 17 – Lubrication
    • Engine oil
    • Engine oil specification
    • Oil capacities
    • Checking engine oil level
    • Parts of lubrication system
    • Oil pump, oil sump – assembly overview, engine codes BKC, BLS, BXE
    • Oil pump, oil sump – assembly overview, engine codes BRM
    • Removing and installing sump
    • Removing and installing oil pump
    • Oil filter bracket, oil pressure, oil cooler and oil supply line
    • Assembly overview – oil filter bracket and oil cooler
    • Removing and installing oil filter bracket with oil cooler
    • Checking oil pressure and oil pressure switch
    • Assembly overview – oil supply line to turbocharger
    • Removing and installing oil supply line to turbocharger
  • 19 – Cooling
    • Parts of the cooling system
    • Parts of cooling system – body side, engine codes BLS, BRM
    • Parts of cooling system – body side, engine codes BKC, BXE
    • Parts of cooling system – engine side, engine codes BLS, BRM
    • Parts of cooling system – engine side, engine codes BKC, BXE
    • Coolant hose connection diagram
    • Draining and filling coolant
    • Removing and installing radiator fan V7 and radiator fan 2 V177
    • Removing and installing radiator
    • Removing and installing coolant pump
    • Removing and installing thermostat
    • Checking cooling system for leaks
    • Checking oil cooler for leaks
  • 20 – Fuel supply system
    • Safety precautions when working on fuel supply system
    • Rules for cleanliness
    • Fuel tank, models with front-wheel drive
    • Assembly overview – fuel tank
    • Draining fuel tank
    • Removing and installing fuel tank
    • Removing and installing fuel delivery unit
    • Removing and installing fuel gauge sender
    • Checking fuel pump
    • Repairing fuel supply system
    • Assembly overview – fuel filter
    • Removing and installing fuel cooler
    • Checking tandem pump
    • Removing and installing tandem pump
    • Electronic power control (EPC)
    • Function of EPC system
    • Assembly overview – accelerator pedal module
    • Removing and installing accelerator pedal module
  • 21 – Turbocharging/supercharging
    • Charge air system with turbocharger
    • Safety precautions
    • Rules for cleanliness
    • Charge air system with turbocharger, engine codes BKC, BXE
    • Turbocharger – Assembly overview, engine codes BKC, BXE
    • Removing and installing turbocharger, engine codes BKC, BXE
    • Parts of charge air cooling – Assembly overview, engine codes BKC, BXE
    • Charge air system with turbocharger, engine codes BLS, BRM
    • Turbocharger – Assembly overview, engine codes BLS (without diesel particulate filter), BRM
    • Removing and installing turbocharger, engine codes BLS (without diesel particulate filter), BRM
    • Turbocharger – Assembly overview, engine code BLS (with diesel particulate filter)
    • Removing and installing turbocharger, engine code BLS (with diesel particulate filter)
    • Parts of charge air cooling – Assembly overview, engine codes BLS, BRM
    • Hose connections
    • Hose connections
    • Removing and installing charge air cooler
    • Removing and installing charge air cooler
    • Checking charge air system for leaks
    • Vacuum hoses for connection diagram
    • Vehicles with engine codes BKC, BXE
    • Vehicles with engine codes BLS, BRM
  • 23 – Mixture preparation – injection
    • Diesel direct injection system
    • Safety precautions
    • Rules for cleanliness
    • Fitting locations overview
    • Assembly overview – unit injector
    • Removing and installing unit injector
    • Removing and installing unit injector O-rings
    • Assembly overview – intake manifold
    • Removing and installing intake manifold
    • Removing and installing intake pipe with exhaust gas recirculation potentiometer G212 and exhaust gas recirculation valve N18 , engine codes BLS, BRM
    • Dismantling and assembling intake pipe with with exhaust gas recirculation potentiometer G212 and exhaust gas recirculation valve N18 , engine codes BLS, BRM
    • Removing and installing intake manifold flap motor V157
    • Assembly overview – air filter
    • Connection diagram for charge pressure control, engine codes BKC, BXE
    • Connection diagram for solenoid valve block, engine codes BKC, BXE
    • Removing and installing engine speed sender G28
    • Removing and installing engine speed sender G28
    • Removing and installing automatic glow period control unit J179
    • Engine control unit
    • Reading and clearing engine control unit fault memory
    • Adapting functions and components
    • Removing and installing engine control unit
  • 26 – Exhaust system
    • Exhaust system
    • Parts of exhaust system – Assembly overview
    • Removing and installing front exhaust pipe
    • Connecting and disconnecting front and rear silencers
    • Stress-free alignment of exhaust system
    • Exhaust gas recirculation system
    • Parts of exhaust gas recirculation – Assembly overview
    • Parts of the exhaust gas recirculation cooler – Assembly overview, engine codes BLS,
      BRM
    • Removing and installing exhaust gas recirculation cooler
    • Check mechanical exhaust gas recirculation valve, engine codes BKC, BXE
  • 28 – Glow plug system
    • Checking glow plug system
    • Checking, removing and installing glow plugs

Technical information should always be available to the foremen and mechanics, because their careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed.

Edition: 05.2007 (MEX5R006420)
Language: English
Format: PDF
Pages: 282

VW 4-Cylinder Diesel Engine With Unit Injector Workshop Manual PDF free online

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