Diesel Engine 4 Cylinder With Unit Injector

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Service

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

Edition 05.2007

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Service Department. Technical Information

This is the cut pages sample. Download all 282 page(s) at: ManualPlace.com
 Service
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

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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R006420

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4-cylinder diesel engine ewith unit injector - Edition 05.2007
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00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Checking and adjusting assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.5 Assembly mounting - Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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1.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.2 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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1.3 Assembly overview - poly-V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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1.4 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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1.5 Removing and installing poly-V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Renewing crankshaft oil seal (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Removing and installing sealing flange - pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4 Renewing crankshaft sealing flange - flywheel end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.5 Removing and installing dual-mass flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.3 Identification of upper crankshaft bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4 Pulling needle bearing out of and driving into crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4 Pistons and connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.2 Checking piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.4 Piston rings, cylinder bore and piston installation position . . . . . . . . . . . . . . . . . . . . . . . . . . 54

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.3 Removing, installing and tensioning toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
1.4 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1.5 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Checking axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.3 Seal bearing caps 1 and 5 contact surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.5 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.6 Renewing valve stem oil seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.7 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Contents i
 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

2.8 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Engine oil specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.3 Checking engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2 Parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.1 Oil pump, oil sump - assembly overview, engine codes BKC, BLS, BXE . . . . . . . . . . . . . . 98
2.2 Oil pump, oil sump - assembly overview, engine codes BRM . . . . . . . . . . . . . . . . . . . . . . 100
2.3 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.4 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Oil filter bracket, oil pressure, oil cooler and oil supply line . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Assembly overview - oil filter bracket and oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Removing and installing oil filter bracket with oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.4 Assembly overview - oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.5 Removing and installing oil supply line to turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1 Parts of the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.1 Parts of cooling system - body side, engine agencodes BLS, BRM
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1.2 Parts of cooling system - body side, by V engine codes BKC, BXE . . o. t .gu. . . . . . . . . . . . . . . . . .
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1.3 Parts of cooling system - engineoris side, engine codes BLS, BRM . . . . . n.te.e . . . . . . . . . . . . .
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1.4 Parts of cooling system - sengine
au side, engine codes BKC, BXE . . . . . . . .r a.c . . . . . . . . . . . 123
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1.5 Coolant hose connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

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1.6 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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1.7 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 130
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1.8 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
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1.9 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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1.10 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re 136

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1.11 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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1.12 Checking oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3 Fuel tank, models with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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3.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

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3.2 Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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3.3 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

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3.5 Removing and installing fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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3.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

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4 Repairing fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
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4.2 Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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4.3 Checking tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
4.4 Removing and installing tandem pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
5 Electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
5.2 Assembly overview - accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
5.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

ii Contents
 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

1 Charge air system with turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Charge air system with turbocharger, engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . 175
2.1 Turbocharger - Assembly overview, engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . . . 175
2.2 Removing and installing turbocharger, engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . 177
2.3 Parts of charge air cooling - Assembly overview, engine codes BKC, BXE . . . . . . . . . . . . 183
3 Charge air system with turbocharger, engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . 185
3.1 Turbocharger - Assembly overview, engine codes BLS (without diesel particulate filter), BRM
...................................................................... 185
3.2 Removing and installing turbocharger, engine codes BLS (without diesel particulate filter),
BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.3 Turbocharger - Assembly overview, engine code BLS (with diesel particulate filter) . . . . 195
3.4 Removing and installing turbocharger, engine code BLS (with diesel particulate filter) . . . . 196
3.5 Parts of charge air cooling - Assembly overview, engine codes BLS, BRM . . . . . . . . . . . . 198
4 Hose connections
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4.1 Hoseby V connections . . . . . . . . . . . . .t g. u.a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5 thorisRemoving and installing charge air coolerntee .o . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.1 au Removing and installing charge air cooler . r.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
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6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

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7 Vacuum hoses for connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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7.1 Vehicles with engine codes BKC, BXE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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7.2 Vehicles with engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

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23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

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1 Diesel direct injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

t to the co

1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
rrectne

1.3 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

1.4 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
ss

1.5 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

o
cial p

1.6 Removing and installing unit injector O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

inform
mer

1.7 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

atio

1.8 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

om

n
c

1.9 Removing and installing intake pipe with exhaust gas recirculation potentiometer G212 and
i
or

n thi
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exhaust gas recirculation valve N18 , engine codes BLS, BRM . . . . . . . . . . . . . . . . . . . . 233
t

sd
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1.10 Dismantling and assembling intake pipe with with exhaust gas recirculation potentiometer
pr

cum
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fo

G212 and exhaust gas recirculation valve N18 , engine codes BLS, BRM . . . . . . . . . . . . 234
en
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1.11 Removing and installing intake manifold flap motor V157 . . . . . . . . . . . . . . . . . . . . . . . . . . 235
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1.12 Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
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1.13 Connection diagram for charge pressure control, engine codes BKC, BXE . . . . . . . . . . . . 238
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1.14
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Connection diagram for solenoid valve block, engine codes BKC, BXE . . . . . . . . . . . . . . 238
AG.

1.15 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

1.16 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.17 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 240
2 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.1 Reading and clearing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
2.2 Adapting functions and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
2.3 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

1 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
1.1 Parts of exhaust system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
1.2 Removing and installing front exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.3 Connecting and disconnecting front and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Contents iii
 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

1.4 Stress-free alignment of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.1 Parts of exhaust gas recirculation - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 262
2.2 Parts of the exhaust gas recirculation cooler - Assembly overview, engine codes BLS,
BRM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
2.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.4 Check mechanical exhaust gas recirculation valve, engine codes BKC, BXE . . . . . . . . . . 272

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

1 Checking glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
1.1 Checking, removing and installing glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

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iv Contents
 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

00 – Technical data
1 Technical data
Engine number ⇒ page 1
Engine data ⇒ page 1

1.1 Engine number

The engine number (“Engine code” and “Serial number”) can be
found on the join between engine and gearbox -arrow-.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (up to 3 code letters) represents the “engine
code letters”, the second part (6 digits) the “serial number”. If more
than 999,999 engines were produced with the same code letters,
the first of the 6 digits is replaced by a letter.
Additionally there is a sticker on the toothed belt guard with “en‐
gine code” and “serial number”.
The engine code is also located on the vehicle data sticker. The
vehicle data sticker is located in the Servicing schedule and in
rear of vehicle in the spare wheel recess or the luggage compart‐
ment floor.

1.2 Engine data olksw

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Engine code orise BKC BLS nte
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BRM BXE
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a 05.05 ▸ 05.05 ▸ 11.04
c ▸ ce 03.06 ▸
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Emissions fulfil EU4 standard EU4 standard Tier 2 EU4 standard

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Capacity l 1.9 1.9 1.9 1.9

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Power output kW at rpm 77/4000 77/4000 74/4000 77/4000

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Torque Nm at rpm 250/1900 250/1900 250/1900 250/1900

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Bore ∅ in mm 79.5 79.5 79.5 79.5

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Stroke mm 95.5 95.5 95.5 95.5

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Valves per cylinder 2 2 2 2

Compression ratio 19.0 19.0 19.0 19.0
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CN at least 51 51 51 51
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
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Catalytic converter yes yes yes yes

Exhaust gas recirculation yes yes yes yes
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Diesel particulate filter no depending on no no

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Lambda control no yes no no

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Turbocharging/supercharging yes yes yes yes

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1. Technical data 1
 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

10 – Removing and installing engine

1 Removing and installing engine
Removing engine ⇒ page 2
Securing engine to assembly stand ⇒ page 15
Installing engine ⇒ page 16
Checking and adjusting assembly mounting ⇒ page 19
Assembly mounting - Torque settings ⇒ page 23

1.1 Removing engine

Special tools and workshop

equipment required
♦ Lifting tackle -2024 A-
♦ Engine support -T10012-
♦ Support clamp -VW 313-
♦ Engine and gearbox sup‐
port -VW 540- agen
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♦ Workshop crane -VAS ed by ara
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♦ Drip tray -V.A.G 1306- or

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drip tray for workshop hoist
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2 Rep. Gr.10 - Removing and installing engine

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

♦ Torque wrench -V.A.G

1331-
♦ Torque wrench -V.A.G agen
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♦ Engine and gearbox jack - horis nte
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♦ Spring-type clip pliers -VAS

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♦ Stepladder -VAS 5085-

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♦ Guide rods -T10093-

♦ Cable ties

1. Removing and installing engine 3

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

Note

♦ Before carrying out further work, disconnect battery earth

strap. First check whether a coded radio is fitted. Obtain anti-
theft code first if necessary.
♦ The engine is removed downwards together with theAGgearbox.
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♦ Renew all cable ties which are opened or
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moving the engine. Refit in the sameriseposition
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When doing any repair work, especially in the engine compart‐
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ment, pay attention to the following due to the cramped condi‐

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tions:
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♦ All wirings (e.g. for fuel, hydraulic system, coolant and re‐
es, in part or in w

frigerant liquid, brake liquid, vacuum) and electrical wir‐

t to the co
ings must be installed in the original way.
♦ Ensure that there is sufficient clearance to all moving or

rrectness of i
hot components.
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Procedure

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– With ignition switched off, disconnect earth strap from battery.

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– Remove engine cover. To do this, pull engine cover upwards

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abruptly at front -arrows A- and then pull forwards out of rear

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fastening -arrow B-.

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– Remove bulkhead in plenum chamber ⇒ General Body Re‐

f

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pairs, Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .

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– Remove air filter housing with air mass meter and connecting
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– Disconnect connector -2- on air mass meter -G70- .

– Pull breather hose -1- and air duct hoses -3- and -5- off.
– Unscrew bolt -4- and take off air filter housing.
Vehicles with engine codes BLS, BRM
– Remove air cleaner housing with air mass meter.

4 Rep. Gr.10 - Removing and installing engine

 AG. Volkswagen AG d
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2006 ➤ , Golf Variant 2007 ➤
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aut 4-cylinder diesel engine with
r a unit injector - Edition 05.2007
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– Disconnect connector -2- on air mass meter -G70- .

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– Pull breather hose -1- off and unhook from bracket -arrow-.
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– Release spring-type clip -3- with spring-type clip pliers -VAS

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5024A- and pull intake hose off air mass meter -G70- .

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hole

spec
– Pull intake manifold -5- off the air duct.
es, in part or in w

t to the co
– Unscrew bolt -4- and take off air filter housing.
Vehicles with diesel particulate filter

rrectness of i
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– Separate the following connectors -arrows- (on bulkhead):
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♦ Connector for charge pressure regulation solenoid valve -

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♦ Connector for bank 1 exhaust gas temperature sender 2 -
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♦ Connector for bank 1 exhaust gas temperature sender 1 -

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– Removing battery ⇒ Electrical system; Rep. Gr. 27 ; Remov‐

ing and installing battery; Vehicles with diesel engine .

– Remove battery tray -arrows-.

Vehicles with direct shift gearbox
If the metal components are touched it is possible to trigger an
electrostatic discharge. This is due to the electrostatic charge of
the human body. This charge can disturb the function of electrical
components of the gearbox and of the shift mechanism.

1. Removing and installing engine 5

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Before working on Mechatronic, touch an earthed object,

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– Do not touch connectors directly. oris nte
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– Turn bayonet connection -1- of connector to left and pull con‐

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nector off gearbox.

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– Release retaining clip -A- off and remove upwards.

– Pull retaining clip -B- off upwards.
– Remove selector lever cable from selector shaft lever and
place on the top.
Vehicles with manual gearbox

– Unclip circlips -1- and -2- from both selector cables.

– Pull off selector cable end-pieces from gearbox selector lever
and relay lever.

6 Rep. Gr.10 - Removing and installing engine

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– Remove cable support bracket from gearbox -arrows- and lay

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– Clamp off pressure line going to slave cylinder with hose
clamps for diameters up to Ø 25 mm -3094- .
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– Remove pressure line -1- out of hose coupling. To do this pull

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retaining clip upwards -arrow-.

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Continuation for all models
AG.

– Loosen bolts -arrows- of assembly mounting on engine just a

bit (less than 1 turn).

– Loosen bolts -arrows- of assembly mounting on gearbox just

a bit (less than 1 turn).
Vehicles with engine codes BLS, BRM

1. Removing and installing engine 7

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Pull connector -arrow 1- off.

Continuation for all models
– Pull vacuum hoses -arrow 2- off.
– Pull vacuum hose -arrow 3- off non-return valve for brake ser‐
vo.

– Pull vacuum hose -arrow- to brake servo off tandem pump.

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– Remove coolant hoses -arrows- to heater heat exchanger on

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– Unscrew earth cable -1-.

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– Remove wiring -2- and -3- on starter.

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– Move wiring clear.

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8 Rep. Gr.10 - Removing and installing engine

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Remove connector -arrow- on coolant temperature sender -

G62- .

– Pull the release pin -arrow 1- and unscrew knurled nut

-arrow 2-.
– Pull central switch for unit injectors off and free wiring harness.

– Disconnect connector -arrow- on fuel temperature sender -

G81- and free wiring.
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– Remove coolant hose between engine and radiator -arrows-.
es, in part or in w

t to the co

WARNING
rrectness of i

♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
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♦ The fuel system is also under pressure! Before opening

the system, place cloths around the connections. Then
nf
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carefully loosen connection to release the pressure!

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♦ Wear eye and hand protection when performing any type

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of repair work on the fuel system!

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1. Removing and installing engine 9

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Mark and pull hoses -2- off and free.

– Remove air pipe. To do this lift retaining clips -1- slightly and
remove the bolt -3- from the transport bracket.

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– Pull coolant hose -arrow- off.
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– Separate fuel supply pipe -3- and fuel return pipe -2-. To do
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– Pull coolant hose -1- off expansion tank.

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– Disconnect connector -arrow- on intake manifold flap motor -

V157- .

10 Rep. Gr.10 - Removing and installing engine

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Take connector -arrow- for Hall sender -G40- out of retainer

and separate.

– Disconnect connector -arrow- on oil pressure switch -F1- .

– Unscrew oil pressure switch.

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– Disconnect connector -arrow- on engine speed sender -G28-

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using assembly tool -T10118- .

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Note

To unlock connector without assembly tool -T10118- , press con‐

rrectness of i

nector to engine speed sender with a screwdriver and raise

release button with a thin wire hook at the same time.
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– Move wire clear.

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– Pull connector strip off glow plugs -arrows-.

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– Bring lock carrier into service position ⇒ General body repairs,
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Vehicles with air conditioner

Note

To prevent damage to condenser or to refrigerant pipes and ho‐

ses, ensure that pipes and hoses are not stretched, kinked or
bent.

WARNING

The air conditioner refrigerant circuit must not be opened.

1. Removing and installing engine 11

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Remove bolts -2- and -3- on refrigerant lines brackets.

To facilitate removing and installing engine without opening re‐
frigerant circuit:
– Remove poly-V-belt ⇒ page 29 .
– Separate air conditioner compressor ⇒ Heating, Air condi‐
tioning system; Rep. Gr. 87 ; Repair work on refrigerant circuit;
Removing and installing air conditioner compressor .
– Secure air conditioner compressor to lock carrier so that re‐
frigerant lines are free of stress.
Continuation for all models
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Alter‐
nator 1.9 l TDI engine .
– Remove radiator ⇒ page 132 .

– Remove left air duct hose, to do this lift retaining clips

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12 Rep. Gr.10 - Removing and installing engine

 Jetta 2005 ➤ , Bora 2006 ➤ , Golf Variant 2007 ➤
4-cylinder diesel engine with unit injector - Edition 05.2007

– Remove bolts -1- and -2-.

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– Remove air hose fromthoturbocharger.
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– Remove connector -2- on radiator outlet coolant temperature
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sender -G83- .
Continuation for all models

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– Remove locking screw -arrow- for front air duct pipe.
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– Remove right-hand and left-hand drive shafts on gearbox ⇒

Running gear, axles, steering; Rep. Gr. 40 ; Servicing drive
shafts; Removing and installing drive shafts .
– Remove front exhaust pipe ⇒ page 251 .
– Disengage and pull off connector on engine control unit
⇒ page 245 .

1. Removing and installing engine 13

Diesel Engine 4 Cylinder With Unit Injector
Full download: http://manualplace.com/download/diesel-engine-4-cylinder-with-unit-injector/

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– Open all cable guide risefasteners -arrows-.
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– Remove wiringss harness from cable guide on longitudinal mem‐ r ac
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– Pull off or disconnect all other electrical connections from en‐
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– Separate all connection, coolant, vacuum and intake hoses

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– Unscrew bolt -1 - first.
– Unscrew bolts -2- and -3- and take pendulum support off.

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– Insert engine support -T10012- in engine and gearbox jack -
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Note

Support pins must be secured to engine bracket -T10012- as

shown.

– Fit engine bracket -T10012- to cylinder block with bolt -

M10×25/8.8- and tighten to approx. 40 Nm.
– Raise engine and gearbox slightly using engine and gearbox
jack -V.A.G 1383 A- .

Note

To remove securing bolts use step ladder -VAS 5085- .

– Unbolt assembly mounting on engine side from engine bracket

-arrows-.

14 Rep. Gr.10 - Removing and installing engine

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