VW 4-cylinder Injection Engine (1.6L, direct injection) Workshop Manual

The 4-cyl. Injection Engine (1.6L, direct injection) is installed in the Volkswagen Jetta 2005 -, Bora 2006 –Engine ID: BLF

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 system
20 – Fuel supply system
24 – Mixture preparation, Injection
26 – Exhaust system
28 – Ignition 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 engine and gearbox support VAS 6095
    • Installing engine
    • Checking and adjusting assembly mounting
    • Assembly mountings
  • 13 – Crankshaft group
    • Dismantling and assembling engine
    • Overview
    • Belt drive – Assembly overview
    • Chain drive – Assembly overview
    • Removing and installing poly V-belt
    • Removing and installing control housing
    • Removing and installing sealing flange and flywheel
    • Flywheel end – Assembly overview
    • Renewing crankshaft oil seal – belt pulley end
    • Tighten bolt for poly V-belt sprocket – crankshaft
    • Renewing crankshaft sealing flange -flywheel end-
    • Removing and installing flywheel
    • Removing and installing crankshaft
    • Crankshaft dimensions
    • Dismantling and assembling pistons and conrods
    • Pistons and conrods – Assembly overview
    • Check piston
    • Piston and cylinder dimensions
  • 15 – Cylinder head, valve gear
    • Cylinder head
    • Cylinder head – Assembly overview
    • Removing and installing camshaft housing
    • Removing and installing cylinder head
    • Checking valve timing
    • Adjusting valve timing
    • Check compression pressures
    • Repairing valve gear
    • Valve gear – Assembly overview
    • Checking camshaft axial clearance
    • Reworking valve seats
    • Checking valve guides
    • Renewing valve stem seals
  • 17 – Lubrication
    • Removing and installing parts of lubrication system
    • Engine oil
    • Parts of the lubrication system – Assembly overview
    • Oil cooler – Assembly overview
    • Removing and installing oil sump
    • Removing and installing oil pump
    • Removing and installing oil cooler
    • Checking oil pressure and oil pressure switch
  • 19 – Cooling system
    • Removing and installing parts of cooling system
    • Parts of cooling system – body side – Assembly overview
    • Parts of cooling system engine side (thermostat side) – Assembly overview
    • Parts of cooling system engine side (coolant pump side) – Assembly overview
    • Coolant hose schematic 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
    • Check cooling system for leaks
  • 20 – Fuel supply system
    • Removing and installing parts of fuel supply system
    • Safety precautions when working on fuel supply system
    • Rules for cleanliness
    • Fuel tank – Assembly overview
    • Emptying fuel tank
    • Removing and installing fuel tank
    • Fuel fliter – Assembly overview
    • Removing and installing fuel filter
    • Repairing fuel supply
    • Safety precautions when working on fuel supply system
    • Rules for cleanliness
    • Crash fuel shut-off
    • Removing and installing fuel delivery unit
    • Removing and installing fuel gauge sender G
    • Checking fuel pump
    • Removing and installing high-pressure pump
    • Servicing electronic power control (EPC)
    • Function of EPC system
    • Accelerator pedal module – Assembly overview
    • Removing and installing accelerator pedal module
    • Activated charcoal filter system
    • Functional check
    • Activated charcoal filter system – Assembly overview
    • Checking fuel tank breather
  • 24 – Mixture preparation, Injection
    • Repairing injection system
    • General notes on injection
    • Safety precautions
    • Rules for cleanliness
    • Fitting locations overview
    • Technical data
    • Air cleaner/engine cover – Assembly overview
    • Removing and installing engine cover with air cleaner
    • Intake manifold – Assembly overview
    • Removing and installing intake manifold
    • Fuel rail with injectors – Assembly overview
    • Removing and installing fuel rail
    • Removing and installing injectors
    • Cleaning throttle valve module J338
    • Checking components
    • Check vacuum reservoir in intake manifold for leaks
    • Check function of intake manifold flap
    • Checking intake air preheating
    • Engine control unit
    • Reading and erasing engine control unit fault memory
    • Removing and installing engine control unit
  • 26 – Exhaust system
    • Removing and installing parts of exhaust system
    • Catalytic converters and attachments – Assembly overview
    • Silencer with mountings – Assembly overview
    • Removing and installing exhaust manifold
    • Removing and installing pre-catalytic converter with exhaust manifold
    • Connecting and disconnecting front and rear silencers
    • Aligning exhaust system free of stress
    • Exhaust gas recirculation system
    • Assembly overview – Exhaust gas recirculation system
    • Removing and installing exhaust gas recirculation valve N18
  • 28 – Ignition system
    • Repairing ignition system
    • Safety precautions
    • Assembly overview – ignition system
    • Removing and installing ignition coils with output stage
    • Spark plug test data

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: 08.2005 (MEX5R007820)
Language: English
Format: PDF
Pages: 206

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