Volkswagen Jetta 2005 User Manual
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Service
Workshop Manual
Jetta 2005 ➤
Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct
injection)
Engine ID
Edition 08.2005
BLF
Service Department. Technical Information
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Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Re pa ir G ro up
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
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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R007820
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Securing engine to engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.4 Checking and adjusting assembly mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.5 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Dismantling and assembling engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2 Belt drive - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3 Chain drive - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.4 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.5 Removing and installing control housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 Removing and installing sealing flange and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.1 Flywheel end - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.2 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3 Tighten bolt for poly V-belt sprocket - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.4 Renewing crankshaft sealing flange -flywheel end- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.5 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3 Removing and installing crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Dismantling and assembling pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.1 Pistons and conrods - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2 Check piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.1 Cylinder head - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.2 Removing and installing camshaft housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.4 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.5 Adjusting valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
1.6 Check compression pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2 Repairing valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.1 Valve gear - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2.2 Checking camshaft axial clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.3 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.4 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.5 Renewing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1 Removing and installing parts of lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.1 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
1.2 Parts of the lubrication system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Contents i
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
1.3 Oil cooler - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.4 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.5 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.6 Removing and installing oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.7 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
19 - Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1 Removing and installing parts of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
1.1 Parts of cooling system - body side - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Parts of cooling system engine side (thermostat side) - Assembly overview . . . . . . . . . . . . 98
1.3 Parts of cooling system engine side (coolant pump side) - Assembly overview . . . . . . . . 99
1.4 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.5 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.6 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 105
1.7 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
1.9 Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
1.10 Check cooling system for leaks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1 Removing and installing parts of fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
1.3 Fuel tank - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
1.4 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
1.5 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Fuel fliter - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
1.7 Removing and installing fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2 Repairing fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.1 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 126
2.2 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.3 Crash fuel shut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.4 Removing and installing fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
2.5 Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.6 Checking fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
2.7 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3 Servicing electronic power control (EPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.1 Function of EPC system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3.2 Accelerator pedal module - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.3 Removing and installing accelerator pedal module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.1 Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.2 Activated charcoal filter system - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.3 Checking fuel tank breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
24 - Mixture preparation, Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1 Repairing injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
1.2 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
1.3 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
1.4 Fitting locations overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
1.5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.6 Air cleaner/engine cover - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
1.7 Removing and installing engine cover with air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
1.8 Intake manifold - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
ii Contents
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
1.9 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
1.10 Fuel rail with injectors - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.11 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.12 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
1.13 Cleaning throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2 Checking components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.1 Check vacuum reservoir in intake manifold for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.2 Check function of intake manifold flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.3 Checking intake air preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
3 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.1 Reading and erasing engine control unit fault memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
3.2 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1 Removing and installing parts of exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
1.1 Catalytic converters and attachments - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . 184
1.2 Silencer with mountings - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.3 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.4 Removing and installing pre-catalytic converter with exhaust manifold . . . . . . . . . . . . . . . . 188
1.5 Connecting and disconnecting front and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
1.6 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2 Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.1 Assembly overview - Exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
2.2 Removing and installing exhaust gas recirculation valve N18 . . . . . . . . . . . . . . . . . . . . . . 195
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1 Repairing ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
1.2 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.3 Removing and installing ignition coils with output stage . . . . . . . . . . . . . . . . . . . . . . . . . . 198
1.4 Spark plug test data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Contents iii
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
iv Contents
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
00 – Technical data
1 Technical data
Engine number ⇒ page 1
Engine data ⇒ page 2
1.1 Engine number
Engine code and engine number can be found on the sticker
-arrow- on the control housing.
The engine code is also on the vehicle data plate and on the
crankcase above the gearbox.
The engine number consists of up to nine characters (alphanu‐
meric). The first part (maximum 3 characters) makes up the
“engine code”, and the second part (6 characters), the “serial
number”. If more than 999,999 engines with the same engine
code are produced, the first of the six characters is replaced with
a letter.
If there is no sticker and you need the “engine codes” and the
“serial number”, proceed as follows:
– Removing battery ⇒ Electrical system; Rep. Gr. 27 ; Remov‐
ing and installing battery; Vehicles with petrol engine .
– Open the cover -1- of the electronics box and remove the cable
-2-.
– Remove bolts -arrows- and battery carrier.
– Read the engine code and the serial number on the left of the
cylinder block -arrow-.
Install in reverse order of removal. During this step, observe the
following:
– Install the battery and observe the respective measures after
connecting the battery ⇒ Electrical system; Rep. Gr. 27 ; Re‐
moving and installing battery; Models with petrol engine .
Jetta 2005 ➤ , Bora 2006 ➤
1. Technical data 1
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
1.2 Engine data
Engine code BLF
Manufactured 08.05 ▸
Emissions fulfil EU 4 Standard
Displacement
Output kW at rpm 85/6000
Torque Nm at rpm 155/4000
Bore ∅ mm 76,5
Stroke mm 86,9
Compression ratio 12,0
Valves per cylinder 4
RON min. 95 Unleaded
Injection, ignition Motronic MED 9.5.10
Mixture formation homogeneous
Variable valve timing yes
Knock control 1 sensor
Lambda regulation 2 probes
Three-way catalytic converter yes
Exhaust gas recirculation yes
Secondary air system no
Electronic power control yes
3
cm
1598
2 Rep. Gr.00 - Technical data
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
10 – Removing and installing engine
1 Removing and installing engine
Removing engine ⇒ page 4
Fastening the engine to the assembly stand ⇒ page 14
Installing engine ⇒ page 16
Checking and adjusting assembly mounting ⇒ page 20
Assembly mounting ⇒ page 22
Special tools and workshop
equipment required
♦ Hose clamp to Ø 25 mm
-3094-
♦ Multi-point bit 19 mm
-3077-
♦ Multi-point bit 18 mm
-3353-
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1332-
♦ Engine and gearbox jack -
V.A.G 1383 A-
Jetta 2005 ➤ , Bora 2006 ➤
1. Removing and installing engine 3
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
♦ Spring-type clip pliers -VAS
5024 A-
♦ Vehicle diagnosis, testing
and information system VAS 5051-
♦ or vehicle diagnosis and
service information system
-VAS 5052-
♦ Double ladder -VAS 5085-
♦ Drip tray -VAS 6208-
♦ Engine bracket -T40075-
♦ Engine bung set -VAS
6122-
♦ Grease -G 000 100-
1.1 Removing engine
Note
♦
In subsequent work sequences the battery earth strap must
be disconnected. Therefore first check whether a coded radio
is fitted. Obtain radio code first if necessary.
♦
The engine is removed downwards together with the gearbox.
♦
Observe rules for cleanliness ⇒ page 115 .
♦
All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
♦
Pull engine coolant hoses off with spring-type clip pliers -VAS
5024 A- .
4 Rep. Gr.10 - Removing and installing engine
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ All wirings (e.g. for fuel, hydraulic system, activated char‐
coal canister system, coolant and refrigerant liquid, brake
liquid, vacuum) and electrical wirings are to be installed in
the original way.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
– With ignition switched off disconnect battery earth strap ⇒
Electrical system; Rep. Gr. 27 ; Disconnecting and connecting
the battery .
– Remove engine cover with air cleaner ⇒ page 161 .
– Removing battery ⇒ Electrical system; Rep. Gr. 27 ; Remov‐
ing and installing battery; Vehicles with petrol engine .
– Open the cover -1- of the electronics box and remove the cable
-2-.
– Remove bolts -arrows- and battery carrier.
– Disconnect rubber bellows -1- from air duct -2-.
– Release both locking devices and take air duct -2- off.
1. Removing and installing engine 5
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Remove warm air collector plate -arrows-.
– Remove pre-catalytic converter with exhaust pipe from ex‐
haust manifold -arrows-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. Gr. 50 ; Noise insulation .
– Remove right and left front part of wheel housing liner ⇒ Gen‐
eral body repairs, exterior; Rep. Gr. 66 ; Wheel housing liner;
Removing and installing front wheel housing liner .
– Drain coolant ⇒ page 102 .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. Gr. 50 ; Body front; Lock carrier service posi‐
tion .
For subsequent work sequences the lock carrier must be sup‐
ported on the longitudinal member.
– Support the lock carrier on one side using the multi-point bit
18 mm -3353- .
– Support the lock carrier on the other side using the multi-point
bit 19 mm -3077- .
– Unscrew intake connecting piece on lock carrier -arrows-.
6 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Pull coolant hose -1- off expansion tank.
– Pull vacuum hose -2- off activated charcoal canister and wind‐
screen washer system reservoir -arrow- and lay free.
WARNING
The fuel line is under pressure! Wear protective glasses and
clothing to avoid injuries and skin contact. Before loosening
lines, wrap a cloth around the connection. Then release pres‐
sure by carefully removing the line.
– Disconnect fuel supply line -3- (press locking ring inwards) and
collect escaping fuel with a cloth.
– Disconnect breather line -1- (press locking ring inwards).
– Seal the lines so that the fuel system is not contaminated by
dirt etc.
– Loosen bolts -arrows- of assembly mounting on engine just a
bit (less than 1 turn).
– Remove upper coolant hose from radiator.
Models without auxiliary heating
– Remove coolant hoses -3- and -4- to heat exchanger on bulk‐
head.
– Remove connector -2- and hose -5- from active charcoal filter
system solenoid valve 1 -N80- -6-.
– Remove retainer along with active charcoal filter system sol‐
enoid valve 1 -N80- -6- from intake manifold.
Models with auxiliary heater
Jetta 2005 ➤ , Bora 2006 ➤
1. Removing and installing engine 7
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Remove coolant hose -3- to heat exchanger on bulkhead.
– Remove connector -2- and hose -5- from active charcoal filter
system solenoid valve 1 -N80- -6-.
– Remove retainer along with active charcoal filter system sol‐
enoid valve 1 -N80- -6- from intake manifold.
– Remove coolant hoses -1- and -7- on heater coolant shut-off
valve -N279- .
Continuation for all vehicles
– Pull the vacuum hose -arrow- off brake servo.
– Release the front connector on the engine control unit and pull
it off ⇒ page 179 .
– Unlock duct for engine wiring harness -arrow- and pull off up‐
wards.
– Open wiring bracket -arrows-.
– Take engine wiring harness -1- to control unit out of the wiring
guide.
8 Rep. Gr.10 - Removing and installing engine
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– Move electrical connector -1- free and disconnect.
– Release underneath bracket -2- of the wiring -arrow-.
– Remove nut -1- and pull earth strap -2- off earth point.
– Take engine wiring harness to control unit off the wiring guide.
– Fit the cable with a cable tie to the engine.
– Remove nut -1- and the earth strap -2- from the assembly
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Jetta 2005 ➤ , Bora 2006 ➤
mounting.
– Loosen bolts -arrows- of assembly mounting on gearbox just
a bit (less than 1 turn).
1. Removing and installing engine 9
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Unclip securing clips -1- and -2- on both cables.
– Pull cable end-pieces off gearbox selector lever and relay lev‐
er.
– Remove cable support bracket from gearbox -arrows- and lay
to side.
– Remove clutch slave cylinder -arrows- and lay to side, do not
open pipes.
Caution
Do not operate the clutch pedal anymore after removing the
clutch slave cylinder.
– Unscrew earth wire -1-.
– Remove electrical wirings -2- and -3- on starter and lay to side.
10 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Separate electrical connector -1- for Lambda probe -G39- .
– Disconnect electrical connector -3- for reversing light switch -
F4- .
– Lay engine wiring harness on bracket -2- to side.
– Unscrew nut -arrow- and take retainer for electrical wiring off
threaded stud.
Models with an air conditioning system
– Pull activated charcoal canister off the bracket upwards
-arrow-.
Note
To prevent damage to condenser also to the refrigerant lines/ho‐
ses, ensure that the lines and hoses are not stretched, kinked or
bent.
Jetta 2005 ➤ , Bora 2006 ➤
To facilitate removing and installing the engine without opening
the refrigerant circuit:
– Remove bracket -arrow- for refrigerant lines on right longitu‐
dinal member.
– Remove ribbed belt ⇒ page 29 .
– Remove air conditioner compressor from bracket for ancilla‐
ries ⇒ Heating, Air conditioning system; Rep. Gr. 87 ; Repair
work on refrigerant circuit; Removing and installing air condi‐
tioner compressor .
Note
The air conditioning system wiring must not be opened.
1. Removing and installing engine 11
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Fit air conditioner compressor -2- to lock carrier -1-. To do this
pull e.g. a wire through the right air conditioner compressor
mounting.
– Observe that the wiring is not kinked.
Models with auxiliary heater
– Loosen nut -3-, remove bolt -4- and take exhaust pipe -5- off
auxiliary heater.
– Place drip tray underneath.
– Release spring-type clips of coolant hoses -1- and -2- and pull
coolant hoses off auxiliary heater.
Continuation for all vehicles
– Remove alternator ⇒ Electrical system; Rep. Gr. 27 ; Alter‐
nator; Alternator 1.6 l FSI engine .
– Separate connector -1- at oil level and oil temperature sender
-G266- .
– Unclip retainer -2- for the line to the oil level and oil tempera‐
ture sender -G266- on subframe.
– Unscrew bolt -1- first.
– Unscrew bolts -2- and -3- and take pendulum support off.
12 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Remove bolts -arrows-.
– Remove right-hand drive shaft and left-hand drive shaft ⇒
Running gear, axles, steering; Rep. Gr. 40 ; Servicing drive
shafts; Removing and installing drive shafts .
Models with auxiliary heater
– Remove bolts -1- and -2- and pull coolant hoses off engine
and gearbox. The coolant hoses remain connected.
Continuation for all vehicles
– Remove pre-catalytic converter along with exhaust pipe
⇒ page 183 .
– Pull off/disconnect all other electrical connections and hoses
as necessary from engine and lay to one side.
– Fit all electrical wirings and hoses on engine.
– Fit pin of engine bracket -T40075- to engine front first.
Jetta 2005 ➤ , Bora 2006 ➤
– Fit engine bracket -T40075- to the engine and gearbox jack -
V.A.G 1383 A- .
– Fit engine bracket -T40075- to pin.
– Fit the engine bracket -T40075- to the rear side of the cylinder
head -arrows- and tighten to 20 Nm.
– Lift engine/gearbox assembly lightly.
Note
To remove securing bolts for assembly mounting use double lad‐
der -VAS 5085- .
1. Removing and installing engine 13
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Remove bolts -arrows- of assembly mounting from engine
bracket.
– Remove bolts -arrows- of assembly mounting from gearbox
bracket.
Note
♦
Check whether all hoses and wiring connections between en‐
gine, gearbox and body are disconnected.
♦
Engine with gearbox must be guided carefully when lowered
to prevent damage.
– Pull engine/gearbox assembly forwards as far as possible and
carefully lower.
1.2 Securing engine to engine and gearbox support -VAS 6095-
When working on the engine, the engine should be secured on
the engine and gearbox support -VAS 6095- .
14 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Special tools and workshop
equipment required
♦ Lifting tackle -2024 A-
♦ Workshop crane -
VAS 6100-
♦ Engine and gearbox stand -
VAS 6095-
Jetta 2005 ➤ , Bora 2006 ➤
Procedure
– Move Engine/gearbox jack -V.A.G 1383 A- to a workbench.
– Lower engine/gearbox assembly so that the gearbox is on the
workbench.
– Remove engine/gearbox connecting bolts.
– Press gearbox off engine.
1. Removing and installing engine 15
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Remove lifting tackle -2024 A- as follows and lift off engine/
gearbox jack -V.A.G 1383 A- with workshop crane -VAS
6100- .
Belt pulley end: 2nd hole in hook rail at position 2
Flywheel end: 3rd hole on support bar in position 7
WARNING
The hooks and locating pins must be secured with locking pins
-arrows- to prevent injuries and damages to the engine.
♦ The positions marked 1...4 on the bar must be towards the belt
pulley end.
♦ The holes in the hook rails are counted up from the hook.
– Pull dowel sleeve -arrow B- out of the cylinder block.
– Secure engine to engine and gearbox support -VAS 6095-
-arrows A- and -arrow B-.
1.3 Installing engine
Install in reverse order of removal. During this step, observe the
following:
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ All wirings (e.g. for fuel, hydraulic system, activated char‐
coal canister system, coolant and refrigerant liquid, brake
liquid, vacuum) and electrical wirings are to be installed in
the original way.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
16 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Note
♦
Install all cable ties at the same place when removing.
♦
Hoses must be locked with clamps ⇒ Electronic parts
catalogue“ETKA” .
♦
When performing repair work, renew self-locking nuts and
bolts.
♦
Renew bolts which are tightened with a swing angle as well as
seals and gaskets.
♦
When swinging the assembly in, ensure that clearance exists
between the drive shafts.
– Fit new dowel sleeves to centralize gearbox on engine block.
Jetta 2005 ➤ , Bora 2006 ➤
1. Removing and installing engine 17
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Ensure that the intermediate plate is attached to the sealing
flange and is slided onto the dowel sleeves -arrows-.
– Check clutch release bearing for wear, renew if necessary.
– Lightly grease clutch release bearing, release bearing guide
sleeve and splines on input shaft with grease -G 000 100- . If
necessary clean and remove corrosion.
– Installing and checking clutch and clutch mechanism ⇒ 6-
speed manual gearbox 0AG; Rep. Gr. 30 ; Repairing clutch
control .
– Rock engine to align engine mounting stress-free, loosen en‐
gine mounting to body if necessary.
Note
♦
Checking and adjusting assembly mounting ⇒ page 20 .
♦
Torque settings for assembly mounting ⇒ page 22 .
♦
Connecting bolts for engine/gearbox ⇒ 6-speed manual gear‐
box 0AG; Rep. Gr. 34 ; Removing and installing gearbox .
♦
Electrical connections and routing ⇒ Electrical system; Rep.
Gr. 97 .
– When installing the engine/gearbox assembly, ensure suffi‐
cient clearance to assembly mountings and radiator.
– Install pendulum support ⇒ page 22 .
– Install drive shafts ⇒ Running gear, axles, steering; Rep. Gr.
40 ; Servicing drive shafts; Removing and installing drive
shafts .
– Installing pre-catalytic converter with exhaust pipe
⇒ page 188 .
– Install selector mechanism, adjust if necessary ⇒ 6-speed
manual gearbox 0AG; Rep. Gr. 34 ; Servicing selector mech‐
anism .
– Install hydraulic clutch slave cylinder ⇒ 6-speed manual gear‐
box 0AG; Rep. Gr. 30 ; Repairing clutch control; Assembly
overview - hydraulic system .
– Install air conditioner compressor ⇒ Heating, Air conditioning
system; Rep. Gr. 87 ; Repair work on refrigerant circuit; Re‐
moving and installing air conditioner compressor .
– Install ribbed belt ⇒ page 29 .
– Install bulkhead in plenum chamber ⇒ General Body Repairs,
Exterior; Rep. Gr. 50 ; Plenum chamber bulkhead .
18 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Route engine wiring harness -1- to control unit below and on
the left (in direction of road) of the wiring harness -2-.
– Install battery carrier first and tighten bolts -arrows-.
– Route wiring -2- as shown in the figure and fit to electronics
box -1-.
– Install the battery and observe the respective measures after
connecting the battery ⇒ Electrical system; Rep. Gr. 27 ; Re‐
moving and installing battery; Models with petrol engine .
– Install engine cover with air cleaner ⇒ page 161 .
– Top-up coolant ⇒ page 102 .
– Install noise insulation ⇒ General Body Repairs, Exterior;
Rep. Gr. 50 ; Noise insulation .
– Connect vehicle diagnosis, testing and information system -
VAS 5051- or vehicle diagnosis and service information sys‐
tem -VAS 5052- .
– Interrogate all fault memories and then erase all fault entries
which have been caused when the engine has been removed
and installed.
After erasing the fault memory of the engine control unit gen‐
erate readiness code.
Observe applicable safety precautions during road test.
– Carry out a road test.
– After this, perform a vehicle system test and if necessary, rec‐
tify faults.
Torque settings
Jetta 2005 ➤ , Bora 2006 ➤
Threaded connection
Torque setting
Nuts and bolts M 6 10 Nm
M7 15 Nm
M 8 25 Nm
M10 40 Nm
M12 60 Nm
Connecting bolts for engine/gearbox ⇒ 6-speed manual gear‐
box 0AG; Rep. Gr. 34 ; Removing and installing gearbox .
Bolts for assembly mounting ⇒ page 22
1. Removing and installing engine 19
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
1.4 Checking and adjusting assembly mounting
Checking settings ⇒ page 20
Adjusting assembly mounting ⇒ page 20
1.4.1 Check settings
– Remove engine cover with air cleaner ⇒ page 161 .
The following dimensions must be obtained:
• Between the engine support and the right longitudinal member
must be a distance of -a- = 10 mm at least.
• The edge on the engine support -2- must be parallel to the arm
-1-. Dimension -x- must be the same on top and bottom.
Note
Dimension -a- = 10 mm can be checked e.g. with suitable round
bars.
1.4.2 Adjusting assembly mounting
Special tools and workshop equipment required
♦ Support bracket -10-222 A-
♦ Torque wrench -V.A.G 1332-
If dimension is too small or to large proceed as follows:
– Removing battery ⇒ Electrical system; Rep. Gr. 27 ; Remov‐
ing and installing battery; Vehicles with petrol engines .
20 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Open the cover -1- of the electronics box and remove the cable
-2-.
– Remove bolts -arrows- and battery carrier.
– Fit support bracket -10 - 222 A- before the gas pressure damp‐
er for the front flap using adapter -10 - 222 A/8- .
– Attach trigger snap of spindles to lifting eyes.
– Tension engine with both spindles evenly, do not lift.
Jetta 2005 ➤ , Bora 2006 ➤
– Remove bolts -arrows- of engine assembly mounting.
– Remove bolts -arrows- of gearbox assembly mounting.
– Renew all bolts one after the other (if they had not been re‐
moved when the engine was removed) and screw in loosely.
1. Removing and installing engine 21
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
– Slide the engine with a lever between engine console -1- and
arm -2- until the bolts are centered in the elongated holes:
• Between the engine support and the right longitudinal member
must be a distance of -a- = 10 mm at least.
• The edge on the engine support -2- must be parallel to the arm
-1-. Dimension -x- must be the same on top and bottom.
Note
Dimension -a- can also be checked e.g. with suitable round bars.
– Tighten bolts for engine side assembly mounting
⇒ page 22 .
– Ensure that on gearbox side the edges of the arm -2- and the
gearbox support -1- are parallel with one another. Dimension
-x- must be the same on top and bottom.
– Tighten bolts for gearbox side assembly mounting
⇒ page 22 .
Assembly is carried out in the reverse sequence of removal.
– Install the battery and observe the respective measures after
connecting the battery ⇒ Electrical system; Rep. Gr. 27 ; Re‐
moving and installing battery; Models with petrol engine .
1.5 Assembly mountings
Torque settings
Note
The assembly mounting securing bolts are stretch bolts and must
be replaced.
Engine assembly mounting
A = 20 Nm + 90° (1/4 turn) further
Renew bolts.
B = 40 Nm + 90° (1/4 turn) further
Renew bolts.
C = 60 Nm + 90° (1/4 turn) further
Renew bolts.
22 Rep. Gr.10 - Removing and installing engine
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4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
Gearbox assembly mounting
A = 40 Nm + 90° (1/4 turn) further
Renew bolts.
B = 60 Nm + 90° (1/4 turn) further
Renew bolts.
Pendulum support
A = 40 Nm + 90° (1/4 turn) further
Renew bolts.
B = 100 Nm + 90° (1/4 turn) further
Renew bolts.
Removing: First remove bolt -B- then bolts -A-.
Installing: First tighten bolts -A- then bolt -B-.
Jetta 2005 ➤ , Bora 2006 ➤
1. Removing and installing engine 23
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Jetta 2005 ➤ , Bora 2006 ➤
4-cylinder Injection engine (1.6 l engine, direct injection) - Edition 08.2005
13 – Crankshaft group
1 Dismantling and assembling engine
Note
♦
If large quantities of metal particles or other deposits (caused,
for example, by partial seizure of the conrod bearings) are
found in the engine oil when performing repairs, clean the oil
passages thoroughly and renew the oil filter in order to prevent
further damage from occurring later.
♦
Oil all contact surfaces before beginning with the assembly
work.
Overview ⇒ page 25
Belt drive - Assembly overview ⇒ page 26
Chain drive - Assembly overview ⇒ page 27 .
Removing and installing poly V-belt ⇒ page 29
Removing and installing control housing ⇒ page 31
Note
When working on the engine, the engine should be secured on
the engine and gearbox support -VAS 6095- .
24 Rep. Gr.13 - Crankshaft group
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