VOLKSWAGEN BORA 2006 (01) PDF Document

The engine data for the VOLKSWAGEN BORA 2006 1.9L TDI engine (Engine Codes BKC, BLS, BRM, BXE) is as follows:

The special tools and workshop equipment required for removing and installing the engine on a VOLKSWAGEN BORA 2006 include:

• Lifting tackle -2024 A-
• Engine support -T10012-
• Support clamp -VW 313-
• Engine and gearbox support -VW 540-
• Workshop crane -VAS 6100- or Workshop crane -V.A.G 1202 A-
• Drip tray -V.A.G 1306- or drip tray for workshop hoist -VAS 6208-
• Torque wrench -V.A.G 1331-
• Torque wrench -V.A.G 1332-
• Engine and gearbox jack -V.A.G 1383 A-
• Spring-type clip pliers -VAS 5024A-
• Stepladder -VAS 5085-
• Guide rods -T10093-
• Cable ties

To remove the engine cover on a VOLKSWAGEN BORA 2006, perform the following steps:

Step 1. With ignition switched off, disconnect earth strap from battery.

Step 2. Remove engine cover. To do this, pull engine cover upwards abruptly at front -arrows A- and then pull forwards out of rear fastening -arrow B-.

When removing the engine on a VOLKSWAGEN BORA 2006, you must renew all cable ties which are opened or cut open. When installing the engine, refit them in the same position.

When doing any repair work, especially in the engine compartment of a VOLKSWAGEN BORA 2006, pay attention to the following due to the cramped conditions:

• All wirings (e.g. for fuel, hydraulic system, coolant and refrigerant liquid, brake liquid, vacuum) and electrical wirings must be installed in the original way.
• Ensure that there is sufficient clearance to all moving or hot components.

For VOLKSWAGEN BORA 2006 vehicles with engine codes BKC and BXE, follow these steps to remove the air filter housing:

Step 1. Disconnect connector -2- on air mass meter -G70- .

Step 2. Pull breather hose -1- and air duct hoses -3- and -5- off.

Step 3. Unscrew bolt -4- and take off air filter housing.

When working on the engine of a VOLKSWAGEN BORA 2006, secure it to support clamp -VW 313- of the assembly stand using engine and gearbox support -VW 540- .

The torque settings for the engine assembly mounting on a VOLKSWAGEN BORA 2006 are:

• 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.

The torque settings for the gearbox assembly mounting on a VOLKSWAGEN BORA 2006 are:

• A = 40 Nm + 90° (1/4 turn) further. Renew bolts.
• B = 60 Nm + 90° (1/4 turn) further. Renew bolts.

The torque settings for the pendulum support on a VOLKSWAGEN BORA 2006 are:

• A = 40 Nm + 90° (1/4 turn) further. Renew bolts.
• B = 100 Nm + 90° (1/4 turn) further. Renew bolts.

For removing, first remove bolt -B- then bolts -A-. For installing, first tighten bolts -A- then bolt -B-.

If large quantities of metal particles or other deposits (caused, for example, by partial seizure of the crankshaft or conrod bearings) are found in the engine oil when performing repairs on a VOLKSWAGEN BORA 2006, perform the following:

• Thoroughly clean the oil passages of the oil cooler, the oil spray jets and the oil filter.
• Renew the oil cooler in order to prevent further damage from occurring later.

The torque settings related to the crankshaft toothed belt pulley on a VOLKSWAGEN BORA 2006 are:

• 10 – 20 Nm +45° (1/8 turn) further for item 10.
• 16 – 120 Nm + 90° (1/4 turn) further for item 15.

The torque settings for the toothed belt components on a VOLKSWAGEN BORA 2006 are:

• 2 – 100 Nm (Toothed belt guard upper part).
• 3 – 25 Nm (Rear toothed belt guard).
• 6 – 10 Nm (Sealing grommet).
• 10 – 20 Nm +45° (1/8 turn) further (Sealing grommet).
• 12 – 20 Nm (Tensioning roller).
• 17 – 15 Nm (Toothed belt guard lower part).
• 20 – 10 Nm + 90° (1/4 turn) further (Item 20).
• 23 – 40 Nm + 180° (1/2 turn) further (Item 23).

The test procedure for checking piston projection at TDC on a VOLKSWAGEN BORA 2006 involves:

Step 1. Turn engine clockwise to measure piston projection at TDC.

Step 2. Piston projection at TDC must be measured when installing new pistons or a short engine. Install the appropriate cylinder head gasket depending upon piston projection, according to the following table:

The piston and cylinder dimensions for the basic dimension honing on a VOLKSWAGEN BORA 2006 are:

The wear limits for piston rings in mm when checking the piston ring gap on a VOLKSWAGEN BORA 2006 are:

The wear limits for piston ring-to-groove clearance in mm on a VOLKSWAGEN BORA 2006 are:

When installing an exchange cylinder head on a VOLKSWAGEN BORA 2006:

• The contact surfaces between the bucket tappets and the cam must be oiled before installing the cylinder head cover.
• The plastic protectors fitted to protect the open valves must not be removed until immediately before fitting the cylinder head.
• If the cylinder head is renewed, all the coolant in the system must also be renewed.
• Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the cracks are small and not more than 0.5 mm wide.
• Do not rework valve seats. Only lapping in of valves is permitted.
• Wait about 30 minutes after installing the camshafts before starting the engine. Hydraulic compensation elements must settle (otherwise valves will strike pistons).
• After working on the valve gear, turn the engine carefully at least 2 rotations to ensure that none of the valves make contact when the starter is operated.
• Always renew gaskets and seals.

The cylinder head bolts on a VOLKSWAGEN BORA 2006 must be tightened in four stages in the following sequence:

Stage 1: Tighten initially with torque wrench to 35 Nm.

Stage 2: Tighten to 60 Nm.

Stage 3: Turn further with rigid wrench by 1/4 turn (90°).

Stage 4: Turn further with rigid wrench by 1/4 turn (90°).

It is not necessary to retighten cylinder head bolts after repairs.

For VOLKSWAGEN BORA 2006 vehicles with engine codes BLS, BRM, the cylinder head cover bolts are tightened hand tight in the sequence -1…13- to 10 Nm.

The test procedure for checking the engine oil level on a VOLKSWAGEN BORA 2006 is:

Step 1. Pull out the dipstick, wipe off with a clean cloth and insert it again onto stop.

Step 2. Pull out the dipstick again and read off the oil level.

The markings on the oil dipstick are:

• 1 – Max. mark
• 2 – Min. mark

The areas on the dipstick mean:

• a – Area above grooved section up to max. mark: Do not top up with engine oil!
• b – Oil level in grooved section: Can be topped up with engine oil.
• c – Area from min. mark up to grooved section: Must be topped up, max. 0.5 l of engine oil!

Test prerequisites include Engine oil temperature at least 60°C, and the vehicle must be level (horizontal). Wait a few minutes after switching off the engine to allow the oil to flow back into the sump.

For the VOLKSWAGEN BORA 2006 with engine codes BKC and BXE, the oil capacities are:

• With oil filter change: 3.8 l.
• Without oil filter change: 3.3 l.

For the VOLKSWAGEN BORA 2006 with engine codes BLS and BRM, the oil capacities are:

• With oil filter change: 4.3 l.
• Without oil filter change: 3.8 l.

The torque setting for the oil filter bracket to the cylinder block on a VOLKSWAGEN BORA 2006 is 15 + 90° (1/4 turn) further. Renew bolts.

The tightening torque for the oil pressure switch -F1- on a VOLKSWAGEN BORA 2006 is 20 Nm torque.

The tightening torque for the oil supply pipe to the oil filter bracket on a VOLKSWAGEN BORA 2006 is 22 Nm.

The tightening torque for the lower air duct pipe to the cylinder block on a VOLKSWAGEN BORA 2006 is 15 Nm.

The tightening torque for the upper air duct pipe on a retainer on a VOLKSWAGEN BORA 2006 is 8 Nm.

The test procedure for checking oil pressure and oil pressure switch on a VOLKSWAGEN BORA 2006 is as follows:

Step 1. Remove oil pressure switch -F1- and screw into tester.

Step 2. Screw tester into oil filter bracket in place of the oil pressure switch.

Step 3. Connect brown wire of tester to earth (-).

Step 4. Connect voltage tester -V.A.G 1527 B- using adapter cables from adapter set -V.A.G 1594C – to battery positive (+) and oil pressure switch. LED must not light up.

Step 5. Start engine and increase speed slowly.

Step 6. At 0.55…0.85 bar the LED must light up, otherwise renew oil pressure switch.

Step 7. Increase engine speed further. At 2000 1/min and an oil temperature of 80°C the oil pressure should be min. 2.0 bar.

Step 8. At higher engine speed, oil pressure must not exceed 7.0 bar. If necessary renew oil filter bracket.

If the pressure relief valve opens prematurely when checking pressure relief valve in filler cap on a VOLKSWAGEN BORA 2006, renew the sealing cap.

The test sequence for checking the cooling system for leaks on a VOLKSWAGEN BORA 2006 is:

Step 1. Open cap on coolant expansion tank.

Step 2. Fit coolant system tester -V.A.G 1274- using adapter -V.A.G 1274/8- on expansion tank.

Step 3. Use hand pump on tester to create a pressure of about 1.0 bar.

Step 4. If pressure drops, find leaks and rectify.

Test prerequisites: Engine at operating temperature.

For frost protection down to -35°C when filling coolant on a VOLKSWAGEN BORA 2006, the recommended mixture proportions are 50% Anti-freeze quantity G 12 and 4.0 l Water (quantities are approximate and depend on vehicle equipment).

When doing any repair work, especially in the engine compartment on a VOLKSWAGEN BORA 2006 fuel supply system, pay attention to the following due to the cramped conditions:

• All wirings (e.g. for fuel, hydraulic system, coolant and refrigerant liquid, brake liquid, vacuum) and electrical wirings must be installed in the original way.
• Ensure that there is sufficient clearance to all moving or hot components.
• The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
• The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
• Wear eye and hand protection when performing any type of repair work on the fuel system!

When working on the fuel supply and injection systems of a VOLKSWAGEN BORA 2006, pay careful attention to the following “6 rules” for cleanliness:

• Thoroughly clean all unions and adjacent areas before disconnecting.
• Place removed parts on a clean surface and cover. Do not use fluffy cloths!
• Carefully cover opened components or seal if repairs cannot be carried out immediately.
• Install clean components only. Do not remove replacement parts from packing until immediately before installing. Do not use parts that have not been stored in their packing (e.g. in tool boxes, etc.).
• When system is open: do not work with compressed air if this can be avoided. Do not move vehicle unless absolutely necessary.
• Also ensure that no diesel fuel comes into contact with the coolant hoses. Should this occur, the hoses must be cleaned immediately. Damaged hoses must be renewed.

The installation position of the fuel delivery unit on a VOLKSWAGEN BORA 2006 is such that the tab -2- on the fuel delivery unit must lie between the tongues -1- and -3-, and the -arrow- points in the direction of travel. The fuel delivery unit can only be installed in this position.

The required torque for the locking ring when installing the fuel delivery unit on a VOLKSWAGEN BORA 2006 is 110 Nm.

The specification for the maximum current draw of the fuel pump when checking function and voltage supply on a VOLKSWAGEN BORA 2006 is max. 7.5 Ampere.

If the values measured for the fuel pump current draw are outside the specifications on a VOLKSWAGEN BORA 2006, renew the fuel delivery unit.

The test prerequisites for checking the tandem pump delivery pressure on a VOLKSWAGEN BORA 2006 are:

• Coolant temperature must be at least 85°C.
• Unit injectors OK.
• Fuel filter and fuel lines must not be blocked.
• The non-return valve in the fuel supply hose must be OK.

When checking tandem pump delivery pressure at idling speed on a VOLKSWAGEN BORA 2006, the minimum specified pressure indicated on the pressure gauge is 7.5 bar.

When checking tandem pump delivery pressure at 4000 rpm on a VOLKSWAGEN BORA 2006, the minimum specified pressure indicated on the pressure gauge is 7.5 bar.

The safety precautions when checking the charge air system for leaks on a VOLKSWAGEN BORA 2006 include:

• The fuel and the fuel lines in the fuel system can become very hot (danger of scalding)!
• The fuel system is also under pressure! Before opening the system, place cloths around the connections. Then carefully loosen connection to release the pressure!
• Wear eye and hand protection when performing any type of repair work on the fuel system!

The maximum test pressure for the charge air system when checking for leaks on a VOLKSWAGEN BORA 2006 is 1.3 bar, and this must not be exceeded.

If leaks occur when checking the charge air system for leaks on a VOLKSWAGEN BORA 2006, when doing any repair work observe notes for the charge air system.

The required tightness for the bolts -1- of the camshaft toothed belt pulley when installing the toothed belt on a VOLKSWAGEN BORA 2006 is 25 Nm.

After evenly tightening the inner bolts -2- and then the outer bolts -1- hand-tight to 20 Nm, they should be turned 90° (1/4 turn) further evenly in the same sequence to secure the camshaft toothed belt pulley on a VOLKSWAGEN BORA 2006.

The hub securing bolt -1- on a VOLKSWAGEN BORA 2006 must be tightened to 100 Nm, using counter-hold tool -T10051- .

When installing the toothed belt on a VOLKSWAGEN BORA 2006, the tensioning roller securing nut must be tightened to 20 Nm and 45° (1/8 turn) further.

The specified torque for the front exhaust pipe to turbocharger when installing it on a VOLKSWAGEN BORA 2006 is 7 Nm.

The torque settings for the mounting components when installing the front exhaust pipe with catalytic converter on a VOLKSWAGEN BORA 2006 are:

• Front exhaust pipe to turbocharger: 7 Nm
• Mounting to subframe: 25 Nm
• Strut to gearbox and front exhaust pipe: 40 Nm
• Front cross member to body: 25 Nm

The specified torque for the repair double clamp (M8) when aligning the exhaust system on a VOLKSWAGEN BORA 2006 is 25 Nm.

The specified torque for the repair clamp-type clip (M8) when aligning the exhaust system on a VOLKSWAGEN BORA 2006 is 25 Nm.

The torque settings related to the diesel particulate filter when installing it on a VOLKSWAGEN BORA 2006 with engine code BLS are:

• Diesel particulate filter on turbocharger: 7 Nm
• Diesel particulate filter on cylinder block: 25 Nm

The final tightening torque for the unit injector securing bolt on a VOLKSWAGEN BORA 2006 is 12 Nm and 270° (3/4 turn) further. Turning further can be done in several stages.

The rocker arm shaft securing bolts on a VOLKSWAGEN BORA 2006 must first be evenly tightened hand-tight (inner bolts -2- then outer bolts -1-), and then tightened to 20 Nm and turned 90° (1/4 turn) further evenly in the same sequence.

The lock nut for the adjuster screw on a VOLKSWAGEN BORA 2006 must be tightened to 30 Nm after holding the adjuster screw in the position where significant resistance can be felt (limit stop) and then turning it 180° back from stop.

When installing the accelerator pedal module on a VOLKSWAGEN BORA 2006:

• Fit connector -2- to the accelerator pedal module -5- and slide the rubber grommet -1- onto the connector again.
• Press accelerator pedal module onto securing pins -6-.
• Insert centring pin -7- into hole in floor of vehicle.
• Secure accelerator pedal module with the bolt -3- and fit cover cap -4-.
• Install steering column trim.
• If the accelerator pedal module has been renewed, adapt the accelerator pedal module to the engine control unit.
• If the accelerator pedal module has been renewed on vehicles with automatic gearbox or direct shift gearbox, the kick-down function must be programmed.

The torque setting for the accelerator pedal module to the body on a VOLKSWAGEN BORA 2006 is 10 Nm.

The following must be noted about ceramic glow plugs on a VOLKSWAGEN BORA 2006:

• Ceramic glow plugs are sensitive against bumps and bending.
• For this reason dropped down glow plugs must never be used, even if no damage can be seen obviously (and even if the height was about 2 cm).
• It is absolutely necessary to follow the installation instructions, otherwise there is risk of a pin crack which may result in an engine damage.
• Do not tilt when removing and installing ceramic glow plugs. Remove components hindering the installation.
• The thread of the hole in the cylinder head or the ceramic glow plugs must never be greased or oiled.
• After installing and before the first engine start on the cold engine, always check resistance of all ceramic glow plugs.
• If a defective ceramic glow plug is broken remove all fragments from the engine, otherwise these can cause damage to the engine. Specification: max. 1 Ω. If the specification is exceeded, renew defective ceramic glow plugs.

The procedure for checking metal glow plugs on a VOLKSWAGEN BORA 2006 is:

Step 1. Detach glow plug connectors from glow plugs.

Step 2. Connect cable of voltage tester -V.A.G 1527 B- with clamps from adapter set -V.A.G 1594 C- to battery positive (+).

Step 3. Place test probe of voltage tester -V.A.G 1527 B- on each glow plug one after the other. Diode lights up: glow plug OK., diode does not light up: renew glow plug.

Test requirements include Fuse box/battery glow plug strip fuse OK, Battery charge at least 11.5 V, and Ignition switched off.

Glow plugs on a VOLKSWAGEN BORA 2006 must be installed with jointed wrench -3220- and tightened to 15 Nm.