Engine code BBW Volkswagen Jetta IV

Engine code BBW

Special tools and equipment

1. V.A.G 1306 Drip tray
2. V.A.G 1332 Torque wrench (40 to 200 Nm)
3. VAS 5024 Spring-type clip pliers
4. 3450/2A Guide pins

1. 3450/3 Puller
2. 3452 Key (for polydrive cylinder head bolts)

Removing

Note. During this procedure the battery Ground strap must be disconnected. Therefore, please check whether a coded radio is installed. Obtain the radio code first if necessary.

1. With ignition switched off disconnect battery Ground (GND) strap.
2. Remove engine cover.
3. Drain coolant. Refer to «Cooling system, draining and filling»(ref-254999-S00054482822007052300000) .
4. Remove right side sound insulation.

Refer to NOISE INSULATION (GASOLINE ENGINES), ASSEMBLY OVERVIEW

1. Disconnect fuel supply line (at connection -1-. To do this slide securing ring -2- in union -3-.
2. Seal lines to avoid contamination of fuel system.
3. Remove intake manifold upper part. Refer to «Intake manifold upper part, removing and installing»(ref-254999-S34584153082007052300000) .

Note. Seal the intake ports in the intake manifold lower part with a clean cloth.

1. Remove connections with coolant hoses.
2. Disconnect coolant hose from cylinder head.
3. Remove intake and pressure lines for secondary air pump motor.
4. Disconnect following connections

1. Camshaft variable timing adjustment valve.
2. For Secondary Air Injection (AIR) Pump Motor -V101-.
3. For injectors -N30-, -N31-, -N32-, -N33-, (unclip cable guide).
4. Camshaft position (CMP) sensor -G40

1. Knock Sensor (KS) 1 -G61
2. for Spark plugs (using T10112)

1. Remove bracket with secondary air pump motor.
2. Disconnect all necessary electrical wiring of cylinder head and move aside.
3. Disconnect front exhaust pipe with catalytic converter. Refer to «Engine code BBW»(ref-254999-S13007517332007053000000)
4. Disconnect connector for Heated Oxygen Sensor (H2OS). see scheme 363

1. Take off poly V-belt. Refer to «Poly V-belt, removing and installing»(ref-254999-S08632555142007052300000) .
2. Remove poly V-belt tensioning element.
3. Remove bracket (Refer to «Part I»(ref-254999-S28350265982007052400000) , item 2) from poly V-belt tensioning element.
4. Remove toothed belt guard upper part.

1. Remove cylinder head cover.

1. Turn crankshaft until camshaft is positioned at TDC No. 1 cylinder.

It should be possible to move setting bar 2065 A in camshaft groove.

1. Remove tool.
2. Loosen tensioning roller and remove toothed belt from camshaft pulley.
3. Turn crankshaft back slightly.
4. Remove upper bolt from rear toothed belt guard.

1. Loosen socket head bolts in sequence given and then remove.

Note. Use key 3452 for polydrive cylinder head bolts.

1. Carefully lift cylinder head off.

Installing

Note. There must be no oil or coolant in the cylinder head bolt pockets in the cylinder head. Do not remove new cylinder head gasket from its packing until immediately before installing. Handle new gasket with extreme care. Damage will cause leakage.

1. Place clean cloths in cylinders so that no dirt or emery cloth particles can get in between cylinder wall and piston.
2. Also prevent dirt and emery cloth particles from getting into coolant.
3. Carefully clean sealing surfaces of cylinder head and cylinder block. Ensure thereby that surfaces are not scored or scratched (if abrasive paper is used, grade must not be less than 100)
4. Carefully remove metal particles, emery residue and cloths.

1. If crankshaft has been turned: Set No. 1 cylinder piston to top dead center and then return crankshaft back slightly.

1. To centralize, screw guide pins from 3450/2 A into front outer threaded holes for cylinder head bolts.
2. Install new cylinder head gasket.
3. Install cylinder head, screw in 8 remaining cylinder head bolts and tighten by hand.
4. Remove guide pins through bolt holes with removal from 3450/3. To do this turn removal tool counter-clockwise, until pins are free.

1. Install remaining cylinder head bolts and tighten hand-tight.

1. Tighten cylinder head in tightening sequence as follow
2. Pretighten all bolts to 40 Nm.
3. Then tighten all bolts 1/4 turn (90 ° ) using a wrench.
4. Then tighten all bolts again another 1/4 turn (90 ° ).

Further assembly is reverse of the disassembling procedure.

Note. When turning the camshaft the crankshaft must not be at TDC. Danger of damage to valves/piston crown.

1. Install toothed belt and set timing. Refer to the «Engine codes AEG, AVH, AZG, BEV»(ref-254999-S21739080412007052500000)
2. Install poly V-belt tensioning element.

Tightening torque: 25 Nm

1. Install poly V-belt. Refer to «Poly V-belt, removing and installing»(ref-254999-S08632555142007052300000) .
2. Fill with new coolant. Refer to the «Cooling system, draining and filling»(ref-254999-S00054482822007052300000) .
3. Connect battery Ground (GND) strap.
4. Adapt engine control module to throttle valve control module. Refer to «Exhaust system components, removing and installing»(ref-254999-S11357018042007052300000) , Adapting functions and components.

1. Test drive vehicle and read Diagnostic Trouble Code (DTC) memory.
2. If DTC memory was erased or engine control module has been disconnected from permanent positive supply, regenerate readiness code. Refer to «Adapting components and functions»(ref-254999-S09751715842007052300000) , Adapting functions and components.

Scheme 152

Special tools equipment

1. 3122 B Spark plug wrench
2. T10112 Removal tool
3. V.A.G 1331 Torque wrench (5 to 50 Nm)
4. V.A.G 1763 Compression tester

Requirements

1. Engine oil temperature must be at least 30 ° C.
2. Voltage supply OK.
3. All electrical consumers, e.g. lights and rear window defroster, must be switched off.
4. If the vehicle is equipped with air conditioning, this must be switched off.

1. On models with an automatic transmission, selector lever in position "P" or "N"

Work sequence

1. Remove engine cover.

Engine code AEG

Scheme 153

1. Disconnect black 6-pin connector from ignition coil with final output stage (arrow).

Engine codes AVH, AZG, BBW, BEV

Scheme 154

1. Disconnect black 6-pin connector from ignition coil with final output stage (arrow).

Continued for all engines

Scheme 155

1. Pull fuse No 32 out of fuse holder.

Note. Removing the fuse 32 interrupts the voltage supply to the injectors.

1. Disconnect connectors from outer injectors.
2. Pull spark plug connectors off with tool T10112
3. Remove spark plugs with spark plug socket 3122B.
4. Check compression pressures using compression tester V.A.G 1763 and adapter V.A.G 1763/6.

Note. Using the compression tester. Refer to Operating instructions.

Vehicles with throttle (accelerator) cable

1. Have a second technician fully depress accelerator pedal.

Continuation for all engines

1. Have a second technician operate starter motor.
2. Operate starter until tester shows no further pressure increase.

Compression pressure values

New: 10 to 13 bar

Wear limit: 7.5 bar

Permissible difference between all cylinders: 3 bar

1. Adapt engine control module to throttle valve control module. Refer to «Engine control module Diagnostic Trouble Code (DTC) memory, interrogating and erasing»(ref-254999-S33244134722007052300000) , Adapting functions and components.
2. Generate readiness code again if DTC memory has been erased or engine control module was disconnected from permanent positive. Refer to «Adapting components and functions»(ref-254999-S09751715842007052300000) ; Adapting components and functions.