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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