4 - Cylinder Injection Engine (2.0l Engine) (AXA)

Service
Workshop Manual
Transporter 2004 ➤
5-cylinder diesel engine
Engine ID AXD AXE BLJ BNZ BPC
Edition 03.2018
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Service Department. Technical Information

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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group
15 - Cylinder head, valve gear
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17 - Lubrication
19 - Cooling
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21 - Turbocharging/supercharging
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23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug system
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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 © 2018 Volkswagen AG, Wolfsburg K0058980720

5-cylinder diesel engine - Edition 03.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when using testers and measuring instruments during a road test . . . . 2
2.2 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 Rules for cleanliness during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Rules for cleanliness when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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2.2 Removing
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and installing front torque reaction support eo . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.1 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.2 Crankcase - attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.3 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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1.4 Renewing seal for timing housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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1.5 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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1.6 Removing and installing thread insert for tie bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2.1 Assembly overview – valve timing housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.2 Removing and installing drive plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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3.2 Basic settings for gear train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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3.3 Crankshaft bearing cap identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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4.2 Installation position and allocation of piston to cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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4.3 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Checking piston ring gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.5 Checking ring-to-groove clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6 Checking cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.7 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Contents i
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3 Checking valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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2.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . k.sw. a. g.e.n .A.G. . . . . . . e. n.A.G. d.o.es. . . . . . 53
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2.2 Measuring axial play of camshaft . . . . . . . . . . . . . . .d b. y.V. . . . . . . . . . . . . . . . . . . . . . . .t .gu.a.r 55
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2.3 Removing and installing camshaft . . . . . . . . . . .th.or.is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nte56 eo
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2.4 Removing and installing camshaft drive gear ss.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57r ac
2.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
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3 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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3.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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3.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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3.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.3 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.1 Assembly overview - oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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2.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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2.3 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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2.4 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.2 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Removing and installing thermostat housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.4 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.5 Removing and installing coolant union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.6 Renewing pipe connection for coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.2 Assembly overview – fan support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
1.2 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
1.4 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.2 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.3 Installing hose connections with plug-in connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
ii Contents
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
1.1 Bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.1 Assembly overview - unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.2 Removing and installing unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.3 Removing and installing wiring harness for unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . 118
2.4 Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.5 Visual inspection of unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.1 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.2 Vacuum hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
4 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.1 Removing and installing fuel temperature sender G81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 Assembly overview – intake manifold AG. Volkswagen
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5.3 Assembly overview – intake db
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6 Air filter . . . . . . . . .th.or.i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .te.e.o . . . . . . . . . . . . . . . . . . . 129
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7 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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7.1 Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
itte
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
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hole
spec
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
es, in part or in w
1.2 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
t to the co
1.3 Separating front and rear silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
1.4 Installation position of clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
1.5 Check exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectness of i 135
l purpos
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

2.1 Assembly overview - particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.2 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
nf
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orm
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

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3.1 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 144
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4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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4.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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4.2 Checking mechanical exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
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4.3 Checking electronic exhaust gas recirculation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.1 Removing and installing glow plugs Q10 / Q14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
1.2 Checking glow plugs Q10 / Q14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Contents iii
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iv Contents
00 – Technical data
1 Identification
(VRL011202; Edition 03.2018)
⇒ “1.1 Engine number/engine data”, page 1
1.1 Engine number/engine data

The engine number (“Code letters” and “Serial number”) can be
found on the joint between engine/gearbox ⇒ Self-study pro‐
gramme No. 328 ; .
Additionally there is a sticker on the front of the cylinder head with
“Engine code” and “Serial number”.
The engine code is also included on the vehicle data sticker.
satelettronica
Codes AXD AXE BLJ BNZ BPC
Manufactured 01.03 ► 01.03 ► 08.03 ► 01.06 ► 01.06 ►
Exhaust emis‐ EU3 stand‐ n AGEU3
. Volkstand‐
swagen AGEU3 stand‐ EU4 stand‐ EU4 stand‐
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Displacement l ised 2.5
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a 2.5 2.5
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Power kW at rpmtho 96/3500 128/3500 120/3500 o 96/3500 128/3500
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Torque Nm ats rpm 340/2000 400/2000 400/2000 340/2000 … 400/2000 …
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2300 2300
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Bore Diameter, 81.0 81.0 81.0 81.0 81.0

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Stroke mm 95.5 95.5 95.5 95.5 95.5

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Compression ratio 18.5 18.5 18.5 18.5 18.5

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CN min. 51 51 51 51 51
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Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3

Catalytic converter yes yes yes yes yes
Exhaust gas recirculation yes yes yes yes yes
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Charging yes yes yes yes yes

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Charge air cooling yes yes yes yes yes

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1. Identification 1
2 Safety information
⇒ “2.1 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
⇒ “2.2 Safety precautions when working on the cooling system”,
page 2
⇒ “2.3 Safety regulations for working on fuel supply”, page 3
⇒ “2.4 Safety precautions when working on injection system”,
page 4
2.1 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test instruments and measuring equipment must always be
secured to the rear seat and operated by a second person from
this location.
satelettronica
♦ Operating from the front passenger seat may result in an ac‐
cident caused by releasing the front passenger air bag which
can cause injuries to the person sitting there.
2.2 Safety precautions when working on the

cooling system
WARNING
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The cooling system is under pressure owhen
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Danger of scalding by steam and risehot
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Cover filler cap on expansion
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a tank with a cloth and open care‐ ac
fully to release pressure.
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Caution
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Danger of overheating due to incorrectly fitted cap.

spec
♦ Tighten cap of coolant expansion tank until it engages.

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WARNING
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Observe the following points during all installation work, in par‐

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ticular in the engine compartment, due to the space limitations:

inform
mer
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
atio
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vated charcoal filter system, coolant and refrigerant, brake

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fluid and vacuum) and electrical wiring in their original po‐

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♦ Ensure that there is sufficient clearance to all moving or

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2 Rep. gr.00 - Technical data

Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections are secured with spring-type clips. In case
of repair, only use spring-type clips.
♦ Hose clip pliers - VAS 6340- are recommended to install
spring-type clips.
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
2.3 Safety regulations for working on fuel

supply
Note
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♦ Hose connections are secured with plug-in connectors or a does
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♦ Fuel hoses on engine must be secured with spring-type clips
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♦ Hose clip pliers - VAS 6340- are recommended to install
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spring-type clips.
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♦ Route all the various lines (e.g. for fuel, hydraulics, coolant
s
and refrigerant, brake fluid and vacuum) and electrical
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wiring in their original positions.
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When removing and installing the fuel pump and fuel gauge send‐
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♦ Even before work starts, the extraction hose of a fume extrac‐ t. C rig
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radial fan with a displacement greater than 15 m3/h can be

used providing that motor is not in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
2. Safety information 3
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2.4 Safety precautions when working on in‐
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WARNING
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
rrectness of i
sitions.
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hot components.
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Note the following if testers and measuring instruments have to
on
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be used during a road test:
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♦ Test and measuring instruments must always be secured to
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rear seat and operated by a second person from this location.
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If test and measuring instruments are operated from front pas‐
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WARNING
Secure fault reader to rear seat and operate from this position.
To prevent injuries to persons and/or destruction of the injection

and glow plug system, the following must be noted:
♦ Switch off the ignition before connecting or disconnecting in‐
jection or glow plug system wiring or tester cables.
♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must only be done
with the ignition switched off, as otherwise the control unit for
diesel direction injection system could become damaged.

3 Repair instructions
⇒ “3.1 Rules for cleanliness during work on fuel system”,
page 5
⇒ “3.2 Rules for cleanliness when working on fuel supply system”,
page 5
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⇒ “3.4 Foreign objects in engine”, page 6 utho eo
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3.1 Rules for cleanliness during work on fuel
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If a mechanical fault is found on the turbocharger, e.g. a de‐
spec
stroyed compressor impeller, just renewing the turbocharger is
es, in part or in w
t to the co
not enough. To avoid subsequent damage, the following work
must be carried out:
satelettronica
♦ Check air filter housing, air filter element and intake hoses
rrectness of i
for dirt/soiling.
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♦ Check the whole charge air path and charge air cooler for
foreign objects.
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If foreign objects are found in the charge air system, the charg‐
rm
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ed air routing must be cleaned and the charge air cooler must
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be renewed, if necessary.
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When working on the turbocharger, pay careful attention to the
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♦ Thoroughly clean all joints and surrounding areas before dis‐ t. C rig
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♦ Place removed parts on a clean surface and cover them over.
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Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ Transportation and protective packaging and sealing caps
must be removed only immediately before fitting.
♦ When making repairs, remove oil from connection and hose
ends.
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
3.2 Rules for cleanliness when working on

fuel supply system
When working on the fuel supply/injection system, carefully follow
the “6 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
3. Repair instructions 5
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Transporter 2004 ➤ ho
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♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
rrectness of i
immediately. Damaged hoses must be renewed.
l purpos
3.3 Rules for cleanliness when working on

injection system
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When working on the fuel supply/injection system, carefully follow

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the “6 rules” below:
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♦ Thoroughly clean all joints and surrounding areas before dis‐
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move the vehicle.
♦ 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.
3.4 Foreign objects in engine
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.

10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 7
⇒ “1.2 Securing engine to assembly stand”, page 12
⇒ “1.3 Installing engine”, page 13
1.1 Removing engine
Special tools and workshop

equipment required
satelettronica
AG. Volkswagen AG d
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♦ Hook - 10-222A/2-
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♦ Lifting eye - 2024A/2-

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♦ Lifting tackle - 3033-

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♦ Workshop hoist - V.A.G 1202A- or workshop hoist - VAS 6100- t. C rig
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♦ Torque wrench - V.A.G 1331- (5 to 50 Nm)
1. Removing and installing engine 7

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♦ Engine support - T10220- or engine support - T10342-

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♦ Adapter - T10261-
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♦ Engine and gearbox jack - V.A.G 1383/A- discontinued, use

engine and gearbox jack - VAS 6931-
♦ Spring-type clip pliers - VAS 5024A- discontinued, use hose
rrectness of i
clip pliers - VAS 6340-

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♦ Ladder - VAS 5085- discontinued, use steps - VAS 6292/4-

♦ Engine and gearbox support - VAS 6095-
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♦ Torque wrench - V.A.G 1332- (40 - 200 Nm)

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♦ Engine support - T10224-

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♦ Container for removed parts - V.A.G 1698-

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♦ Cable tie
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The engine is removed downwards with gearbox.
8 Rep. gr.10 - Removing and installing engine

WARNING

♦ Route all the various lines (e.g. for fuel, hydraulics, coolant
and refrigerant, brake fluid and vacuum) and electrical
wiring in their original positions.
hot components.
Note
♦ Leave ignition key in ignition lock to prevent steering lock from

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platform until the splash plates
ss for the brake discs are just
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position regarding accessibility of engine compartment com‐
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♦ Some components cannot be removed, or removed only with
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termine all defective components before removing engine and
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spec
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♦ To prevent damage to removed components, place them in
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the container for removed parts - V.A.G 1698- .
rrectness of i
– With ignition switched off, disconnect battery earth strap.
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– All cable ties which are opened or cut through when engine is
removed must be replaced in the same position when engine
is installed.
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– Remove noise insulation.
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5-cylinder diesel engine -lkEdition
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– Locate adapter - T10261-
horis as shown on central bolt of rear tor‐ tee
que reaction supportauand unscrew torque reaction support
t or
ac
from support mounting.
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– Remove subframe ⇒ Running gear, axles, steering; Rep. gr. du
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40 ; Removing and installing subframe .
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– Drain coolant ⇒ page 78 .
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– Pull radiator coolant hoses off engine using hose clip pliers -
hole
VAS 6340- .
spec
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– Remove coolant expansion tank.
t to the co
– Disconnect all electrical wiring from gearbox, alternator and
starter and lay to side.
rrectness of i
– Pull off or disconnect all other electrical connections as nec‐
l purpos
essary from engine and lay to side.

– Detach all connection, coolant and vacuum hoses/lines from
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– Remove front exhaust pipe ⇒ page 131 .
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– Release charge air cooling connections.
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– Remove connecting pipe between air mass metre and turbo‐
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charger.
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– Remove air filter ⇒ page 129 . Cop py
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– Unscrew support mounting -A- from torque reaction support by c lksw
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– Remove torque reaction support -B-.
Note
Pendulum support bolts must always be renewed.
– Remove air conditioner compressor from cylinder block and

secure at side so that refrigerant lines/hoses are not under
tension.
– Unscrew bolts for vane pump for power-assisted steering. Pull
vane pump together with input gear out of spur gear ⇒ Run‐
ning gear, axles, steering; Rep. gr. 48 .
– Detach central connector from unit injectors.
– Detach fuel lines -arrows- from fuel filter.

– Remove selector mechanism from gearbox ⇒ 0A5 6-speed
manual gearbox ; Rep. gr. 34 ; Repairing selector mecha‐
nism .

– Clamp off supply hose to clutch actuator mechanism with hose

clamps up to 25 mm - 3094- .
– Release securing clip -2- with a screwdriver. Pull pipe/hose

line or plastic line -4- off breather -1-.
– Seal pipe/hose line or plastic line -4- with cap, e.g. from engine
bung set - VAS 6122- and place to one side.
Note
AG. Volkswagen AG d
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Do not operate clutch pedal from this point onwards.
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– Remove selector cable from gearbox ⇒ Automatic gearbox

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– Remove drive shafts from gearbox ⇒ Running gear, axles,
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steering; Rep. gr. 40 ; Removing and installing drive shaft .
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spec
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Vehicles with all-wheel drive
t to the co
– Remove bevel box ⇒ 0A5 6-speed manual gearbox, all -wheel
drive; Rep. gr. 34 ; Removing and installing bevel box .
rrectness of i
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– Detach rear torque reaction support from support mounting.

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– Insert engine bracket - T10224- in engine and gearbox jack -

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– Locate engine support - T10224- on cylinder block and tighten
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Note
♦ The figure shows the old engine and gearbox support VAG
1383 A.
♦ First remove rubber grommet for securing noise insulation.
– Lift engine and gearbox slightly using engine and gearbox jack
- VAS 6931- .

– Unscrew securing bolts -arrows- and remove assembly

mounting-A- completely.
Note
To remove securing bolts, use steps - VAS 6292/4- .
– Remove securing bolts for gearbox mounting -arrows-.

– Carefully lower power unit.
Note
Engine and gearbox must be guided carefully when lowering to

prevent damage to the bodywork.
satelettronica
1.2 Securing engine to assembly stand
Engine codes AXD, AXE and BLJ
When dismantling or assembling engine, secure enginewage
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– Remove engine bracket from cylinder head.

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– Fit lifting eye - 2024A/2- to cylinder block and tighten to 40 Nm

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– Fit engine support - T10220- as shown and tighten to 40 Nm.

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– Attach lifting tackle - 3033- (item 1 and 7) and raise out of en‐
hole
spec
gine and gearbox jack - V.A.G 1202A- using workshop hoist -

es, in part or in w
VAS 6100- or workshop hoist - VAS 6931- .

t to the co
– Secure engine to assembly stand with engine and gearbox

support - T10220- .
rrectness of i
Engine codes BNZ and BPC

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When dismantling or assembling engine, secure engine to as‐

sembly stand using engine bracket - T10342- .
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Sequence of operations
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– Unbolt gearbox.
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– Remove engine bracket from cylinder head.

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– Fit lifting eye - 2024A/2- to cylinder block and tighten to 40 Nm

– Fit engine support - T10342- as shown and tighten to 40 Nm.
– Attach lifting tackle - 3033- (item 1 and 7) and raise out of en‐
gine and gearbox jack - V.A.G 1202A- using workshop hoist -
VAS 6100- or workshop hoist - VAS 6931- .
– Secure engine to assembly stand using engine bracket -
T10342- .
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1.3 Installing engine
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Install in reverse order of removal, observing the following:
rrectness of i
– Finally, bolt mounting bracket to torque reaction support.
l purpos
– Check clutch release bearing for wear and renew if necessary.

– Lightly lubricate clutch release bearing, release bearing guide
nform
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sleeve and splines on input shaft with grease - G 000 100- .

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– Check whether dowel sleeves for aligning engine and gearbox
ion in
are fitted in cylinder block and install if necessary.
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– When installing engine, ensure that there is sufficient clear‐
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ance to drive shafts.
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Specified torques ⇒ page 15 , Power unit mounting
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– Install selector mechanism and adjust cables if necessary ⇒
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6-speed manual gearbox 0A5; Rep. gr. 34 ; Repairing gear
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selector mechanism; Removing and installing selector cables.
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Vehicles with automatic gearbox

– Install selector cable on gearbox ⇒ Automatic gearbox 09C;
Rep. gr. 37 .
– Removing and installing vane pump for power assisted steer‐
ing ⇒ Running gear, axles steering; Rep. gr. 48 .
– Electrical connections and routing ⇒ Electrical system; Rep.
gr. 97 .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 .
– Install bevel box ⇒ 0A5 6-speed manual gearbox, all -wheel
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing drive shaft .
– Install subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe .

– Locate adapter - T10261- as shown on central bolt of rear tor‐

que reaction support and tighten torque reaction support to
support mounting.
– Install front exhaust pipe ⇒ page 131 .
– Bleed clutch actuator mechanism ⇒ Power transmission; Rep.
gr. 30 ; Bleeding clutch system .
– Install noise insulation.
– Add coolant ⇒ page 78 .
– Carry out road test and read all event memories ⇒ Vehicle
diagnostic tester.
Clearance check in RHD models

– Ensure minimum clearance of 15 mm between turbocharger
-A- and brake servo -B- in RHD models. The dimension can
be checked using a tool such as a T bar - 3141- .
Specified torques
Bolted connection Specified torque
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M12 60 Nm
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Deviations
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Front torque reaction sup‐ 50 Nm +90°
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port to cylinder block 1)
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Rear torque reaction sup‐ 50 Nm +90°
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Mounting bracket to front 90 Nm +180°

torque reaction support 1) t to the co
Mounting bracket to rear tor‐ 50 Nm +90°

rrectness of i
que reaction support 1) 2)

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1) Renew bolts.
2)Bolt mounting bracket to subframe first and then mounting
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bracket to torque reaction support.

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Specified torques for assembly mounting ⇒ page 15 .

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2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 15
⇒ “2.2 Removing and installing front torque reaction support”,
page 15
2.1 Assembly overview - assembly mount‐

ings
Engine mounting
Note
Engine mounting bolt -A- must be centred in engine bracket be‐

fore it is tightened.
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Specified torque nte
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Bolt -A- 90 Nm +90°
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Bolt -B- 50 Nm +90°
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Bolt -C- 50 Nm +90°
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– Renew bolts after removing.
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Gearbox mounting
hole
spec
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Specified torques
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Component Specified torque
Bolt -A- 50 Nm +90°
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Bolt -B- 50 Nm +90°

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– Renew bolts after removing.

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2.2 Removing and installing front torque re‐

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– Remove subframe damper weights.
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– Unscrew bolt -1-.
2. Assembly mountings 15
– Unscrew bolts -1- and remove rubber mounting.
– Unscrew bolts -1- and -2-.

– Remove torque reaction support lower part -B-.
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– Unscrew bolts -1- and remove
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part -A-. ho
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13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - crankcase”, page 17
⇒ “1.2 Crankcase - attachments”, page 20
⇒ “1.3 Removing and installing sealing flange on pulley end”,
page 21
⇒ “1.4 Renewing seal for timing housing cover”, page 21
⇒ “1.5 Renewing alternator shaft oil seal”, page 22
⇒ “1.6 Removing and installing thread insert for tie bolt”,
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♦ If large quantities of swarf or metal particles (caused, for ex‐
ility
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are found in the engine oil when performing repairs, clean the
h re
ole,
oil passages thoroughly and renew the engine oil cooler in or‐
spec
der to prevent subsequent damage.
t to the co
♦ Engine must not be set down on oil sump, as this will damage
the oil sump liquid gasket.
rrectne
♦ Secure engine to engine and gearbox support - VAS 6095- to
carry out repairs.
ss o
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1. Cylinder block (pulley end) 17

1 - Noise insulation
❑ If present
2 - Plug
❑ Remove to remove
coolant pump.
❑ 20 Nm
3 - Plug, filter
❑ Remove to remove
coolant pump.
❑ Filter - 070 121 040 A-
may be required when
completing a short en‐
gine.
Note AG. Volkswagen AG d

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Filter - 070 121 040 A- is used to re‐ ised b ara
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❑ 2 Nm
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4 - O-ring
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❑ Renew after removal
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5 - Engine speed sender -
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❑ Removing and installing
⇒ page 158
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❑ 10 Nm
6 - Bolt
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❑ 20 Nm
s
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❑ For gear train housing
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8 - Oil filter housing

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❑ With engine oil cooler.
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❑ Assembly overview ⇒ page 71

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❑ 20 Nm Cop py
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11 - Bolt
❑ 15 Nm
12 - Retaining clip
❑ For oil sump.
14 - Oil pan
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic parts catalogue (ETKA) ⇒ page 68
15 - Tie bolt
❑ If tie bolt needs to be loosened, cylinder head bolts must first be removed.
❑ 30 Nm
18 Rep. gr.13 - Crankshaft group

16 - Sealing flange
❑ Renew seal if damaged.
❑ Removing and installing ⇒ page 21
17 - Cover
18 - Bolt
❑ 10 Nm
19 - Bolt
❑ 50 Nm +90°
20 - Engine support
21 - Thread insert
❑ From above: threaded connection for cylinder head bolt
❑ From below: threaded connection for tie bolt
22 - Torque reaction support
satelettronica
❑ Rear
23 - Bolt
❑ 50 Nm +90°
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1.2 Crankcase - attachments
1 - Alternator agen
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❑ Removing and installing s aut ra
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⇒ Electrical system; s
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Rep. gr. 27 ; Removing un
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and installing alterna‐
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❑ Must not be separated
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from bracket
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2 - Bolt
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❑ 25 Nm
t to the co
3 - Bolt
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❑ 90 Nm +180°
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4 - Front torque reaction sup‐
satelettronica
port
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❑ Upper part
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5 - Front torque reaction sup‐
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port
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6 - Bolt
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7 - Bolt Prote
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❑ 50 Nm +90°
8 - Support mounting
❑ For torque reaction sup‐
port.
9 - Bolt
❑ 20 Nm +90°
10 - Power steering vane pump
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 48 .
11 - Bolt
❑ 40 Nm +90°
12 - Elastic drive coupling
❑ Renew if damaged
13 - Hexagon bolt
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and installing air conditioner com‐
pressor
14 - Air conditioner compressor
❑ Removing and installing ⇒ Heating, air conditioning; Rep. gr. 87 ; Removing and installing air conditioner
compressor

15 - Bracket
❑ For air conditioner compressor.
❑ Note dowel sleeves between bracket/cylinder Vblockwage
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16 - Hub ris
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❑ For alternator shaft. au ra
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❑ Renewing alternator shaft oil seal ⇒ page 22
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17 - Elastic drive coupling
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❑ 50 Nm +90°
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1.3 Removing and installing sealing flange
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on pulley end
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Removing
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satelettronica
– Unscrew bolts -arrows-.
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– Carefully prise off sealing flange.
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♦ Remove remains of sealant from sump and crankcase.
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♦ Clean sealing surfaces.
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Installing
AG.

– Seal joint between sump and crankcase -arrows- with silicone
sealant - D 176 404 A2- .
– Mount new sealing flange.
Note
When installing a new sealing flange, ensure that the bead of

sealant is not “pressed away”.
Specified torques
♦ ⇒ “1.1 Assembly overview - crankcase”, page 17
1.4 Renewing seal for timing housing cover

Special tools and workshop equipment required
♦ Extractor hook - T20143/2-
♦ Assembly tool - T10122-
Removing
Note
Ensure that sealing surface is not damaged when removing seal.

– Carefully remove old seal from its seat using extractor hook -
T20143/2- . wage
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Installing ed by ara
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Install in reverse order of removal, tho
observing
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– Remove oil residues from crankshaft journal with a clean cloth.
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– Pull dry seal -A- onto fitting sleeve - T10122/1- with outside of
seal over sleeve - T10122/2-
rrectne
– Separate the two assembly sleeves.
– Mount fitting sleeve - T10122/2- with seal on crankshaft jour‐
ss
nal.
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mer
satelettronica
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– Press seal into valve timing housing as far as it will go, using
thrust piece - T10122/3- to do so.
1.5 Renewing alternator shaft oil seal


equipment required
satelettronica
AG. Volkswagen AG d
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♦ Assembly tool - T10208- s aut ra
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♦ Extractor hook - T20143-
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♦ Torque wrench - V.A.G 1332-

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Removing
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– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐

h re
hole
ing and installing alternator .

spec
es, in part or in w
t to the co
WARNING
When loosening the threaded connection for the alternator

rrectness of i
drive hub, always hold hub on flats (AF 27) because otherwise
l purpos
the threaded connection inside the gear train housing may be

loosened.
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– Remove hub from alternator shaft. Counterhold hub with com‐

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mercially available ring spanner AF 27 mm.

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1. Cylinder block (pulley end)
– Carefully remove old seal from its seat using extractor hook -
T20143/1- .
Installing
– Remove oil residue from alternator drive shaft using clean
cloth.
– Screw guide sleeve - T10208/1- hand-tight onto drive shaft for

alternator. Carefully slide seal on onto stop.
– Mount thrust piece - T10208/2- and press seal in as far as stop.
WARNING
When tightening the threaded connection for the alternator
satelettronica
drive hub, always hold hub on flats (AF 27) because otherwise
the threaded connection inside the gear train housing may be
loosened.
– Bolt hub to alternator shaft using new bolt.

– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removingagen
AG. Volkswagen AG d
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Specified torques thoris nte
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♦ ⇒ “1.2 Crankcase - attachments”, page 20 ss
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1.6 Removing and installing thread insert for
erm
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tie bolt
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♦ Puller - T10055- t to the co

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The cylinder head bolts are screwed into the thread insert from
the cylinder head side, and the tie bolts from the crankshaft side.

– Move lock carrier into service position: ⇒ General body re‐

pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service
position .
– Remove cylinder head ⇒ page 46 .
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Exterior equipment; Noise insulation .
– Unscrew coolant pipe from sump.
– Loosen subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Removing and installing subframe and lower to floor.
– Remove sump ⇒ page 68 .
– Remove crankshaft ⇒ page 31 .
– Screw old tie bolt into thread insert from above.
– Pull out thread insert using tie bolt and puller - T10055- .
Installing
– Push thread insert into hole to stop, ensuring that the guide is
satelettronica
in the correct position.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 42
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 31
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 67
AG. Volkswagen AG d
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1. Cylinder block (pulley end)
agen
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2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview – valve timing housing cover”,
page 26
⇒ “2.2 Removing and installing drive plate”, page 27
⇒ “2.3 Removing and installing flywheel”, page 28
2.1 Assembly overview – valve timing hous‐

ing cover
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♦ If large quantities
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are found in the engine oil when performing repairs, clean the
ce
le
un
pt
oil passages thoroughly and renew the engine oil cooler in or‐
an
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itte
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der to prevent subsequent damage.
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ility
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♦ Engine must not be set down on oil sump, as this will damage
wit
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the oil sump liquid gasket.
satelettronica
h re
ole,
♦ Secure engine to engine and gearbox support - VAS 6095- to

spec
carry out repairs.

t to the co
1 - Gear train housing cover

rrectne
❑ Must seat on dowel

sleeves.
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❑ Remove to ease remov‐

cial p
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al of gearbox ⇒ Rep. gr.

form
mer
34 ; Removing and in‐

atio
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stalling gearbox; Re‐

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moving gearbox and

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sump ⇒ page 68 .
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❑ Install with silicone seal‐

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ant - D 176 501 A1-

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⇒ page 27 .
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3 - Cylinder block
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❑ With gear train.
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 37
4 - Cylinder head
⇒ page 46
5 - Gear wheel
❑ For coolant pump
coolant pump
⇒ page 90 .
6 - Oil pan
❑ Clean sealing surface
before fitting.
❑ Install with silicone seal‐
ant ⇒ Electronic parts
catalogue (ETKA) .

7 - Bolt
❑ 15 Nm
8 - Seal
9 - Bolt
❑ 20 Nm
10 - Seal
❑ Do not apply additional oil or grease the sealing lip of the oil seal.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Remove to ease removal of gearbox ⇒ Rep. gr. 34 ; Removing and installing gearbox; Removing
gearbox
11 - Cover
12 - Bolt
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❑ 25 Nm
Sealant bead on valve timing housing
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2. Cylinder block, gearbox end 27

♦ Depth gauge
♦ Hexagon bolt M8x50 with M12 hexagon nuts
Loosening and tightening drive plate:
– Secure clutch counterhold - VW 558- to drive plate with hex‐
agon bolt M8x50. Insert M12 hexagon nuts between counter‐
hold and drive plate.
satelettronica
Installation position of counterhold: -A- to loosen, -B- to tighten.
Installing drive plate:
– Position drive plate with shim.
– Fit new bolts and tighten to 30 Nm.
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♦ Measure between through-holes on
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s
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– Fit vernier gauge, and perform measurement at three evenly

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distributed points -1, 2 and 3-. Specification dimension -a-:

18.7 … 20.3 mm.
If specification is not attained:
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– Remove drive plate again and place shim between crankshaft

and drive plate. Tighten bolts to 30 Nm again.
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– Then, tighten bolts to specified torque (turning further can be

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done in several stages).

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Specified torques
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Bolts for drive plate 60 Nm +90°

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♦ Counter-hold tool - 3067- ss c
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Removing
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .
Caution
Risk of severe damage to flywheel!

♦ Do not unscrew bolts with a pneumatic impact wrench or
other power impact wrench. Unscrew them by hand.
♦ When removing the bolts, make sure that the bolt heads
do not come into contact with the flywheel.
– Rotate dual-mass flywheel -A- so that bolts -B- align centrally

with the holes -arrows-.
2. Cylinder block, gearbox end 29

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– Insert counterhold tool - 3067- inedhole
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– Remove flywheel.
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– Insert counterhold tool - 3067- in hole -A- of cylinder block.
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– Tighten bolts.
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5-cylinder
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tho eo
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⇒ “3.1 Assembly overview - crankshaft”, page 31
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⇒ “3.4 Crankshaft dimensions”, page 34
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⇒ “3.5 Measuring axial clearance of crankshaft”, page 34
⇒ “3.6 Measuring radial clearance of crankshaft”, page 35
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3.1 Assembly overview - crankshaft
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1 - Tie bolt
nform
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❑ If tie bolt needs to be
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loosened, cylinder head

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❑ 30 Nm
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❑ Observe installation po‐
sition
3 - Thrust washer
❑ For bearing 4
4 - Bearing shell 4
❑ Crankshaft bearing
identification
⇒ page 33
5 - Crankshaft
❑ If crankshaft is to be re‐
moved, unscrew cylin‐
der head bolts before
loosening crankshaft
bearings.
❑ When installing, ob‐
serve basic settings for
gear train ⇒ page 32 .
❑ Measuring axial clear‐
ance ⇒ page 34 .
❑ Measuring radial clear‐
ance ⇒ page 35
❑ Do not rotate crankshaft
when checking radial
clearance
❑ Crankshaft dimensions ⇒ page 34 .
6 - Gear train housing cover
❑ Install with silicone sealant - D 176 501 A1- ⇒ page 27 .
❑ With seal
❑ Do not apply additional oil or grease the sealing lip of the oil seal.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Renewing seal ⇒ page 21 .
3. Crankshaft 31
7 - Flywheel/drive plate
❑ Removing and installing drive plate ⇒ page 27
❑ Removing and installing flywheel ⇒ page 28
8 - Bolt
❑ 60 Nm +90°
9 - Cylinder block
❑ Dismantling and assembling pistons and conrods ⇒ page 37
10 - Bolt
❑ 20 Nm +90°
11 - Vibration damper
❑ Remove to remove piston rod bearing capwafor genNo. 1ocylinder.
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3.2 Basic settings for gear train
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♦ Special wrench - T10225-
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When installing crankshaft, observe basic settings for gear train. cted agen
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If the basic settings are not performed, the marking on the sender
wheel -arrow- cannot be positioned correctly when installing the
camshaft sprocket.
• Cover ⇒ Item 17 (page 19) removed.

– Position intermediate wheel -arrow- on mark:

Old version
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The marks -arrows- must be aligned.
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Continuation for all versions
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– Install crankshaft in position TDC No. 1 cylinder.

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– Bolt special wrench - T10225- onto crankshaft.
Note
♦ It is only possible to bolt special wrench - T10225- onto crank‐

shaft in one position.
♦ Check intermediate sprocket is still positioned on mark.
The marks on special wrench - T10225- and sealing flange must

align -arrows-.
– Unbolt special wrench - T10225- from crankshaft.
3.3 Crankshaft bearing cap identification

The crankshaft bearing shells are classified during production and
cylinder block and crankshaft sender wheel are marked as shown.
When ordering bearing shells, remove oil sump and baffle plate,
read the coloured mark and allocate the bearing shells accord‐
ingly.
3. Crankshaft 33
• The colour code of the upper bearing shells can be read on

the crankcase into which the crankshaft is to be installed.
• The colour code of the lower bearing shells can be read on the
crankshaft.
Identification of upper crankshaft bearings -arrow- (next to first
crankshaft bearing)
Identification of lower crankshaft bearing -arrow- (on crankshaft

sender wheel)
Colour code on crankcase
satelettronica
Identification Upper bearing shell
G = yellow
R = red
S = black
Colour code on crankshaft

Identification Lower bearing shells
B = blue
G = yellow
R = AG. Volkswagred
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No further honing dimensions are planned at this time.

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-0.022 -0.022
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Basic dimension 58.00 50.90

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-0.037 -0.042
3.5 Measuring axial clearance of crankshaft

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♦ Universal dial gauge holder - VW 387-
♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
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– Screw dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- onto cylinder block and set against crank web.
rrectne
– Press crankshaft against dial gauge by hand and set gauge to
“0”.
ss o
– Push crankshaft away from dial gauge and read off value.
cial p
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Axial clearance:
mer
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• New: 0.07 … 0.231 mm

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• Wear limit: 0.250 mm.

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3.6 Measuring radial clearance of crank‐

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♦ Plastigage
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Note
♦ Do not interchange used bearings.

♦ Bearing shells worn down to nickel layer must be renewed.
– Remove main bearing cap and clean bearing cap and bearing
journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the bearing journal or in the bearing shells.
• The Plastigage must rest in the middle of the bearing shell.
3. Crankshaft 35
– Fit crankshaft bearing cap, and tighten tie bolts. Do not rotate
crankshaft while doing so.
– Remove main bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• New: 0.026 to 0.040 mm
• Wear limit: 0.16 mm.
Specified torques
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 31
AG. Volkswagen AG d
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AG. Volkswagen AG d Transporter 2004 ➤
agen oes
Volksw 5-cylinder
not
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by ara
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nl
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⇒ “4.1 Assembly overview - pistons and conrods”, page 37
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⇒ “4.2 Installation position and allocation of piston to cylinder”, erm
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ility
page 39
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⇒ “4.3 Measuring piston projection at TDC”, page 39
h re
hole
spec
⇒ “4.4 Checking piston ring gap”, page 40
es, in part or in w
t to the co
⇒ “4.5 Checking ring-to-groove clearance ”, page 40
⇒ “4.6 Checking cylinder bores”, page 40
rrectness of i
⇒ “4.7 Piston and cylinder dimensions”, page 41
l purpos
4.1 Assembly overview - pistons and con‐

rods
nform
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Note
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All bearing and running surfaces must be oiled before assembly.
satelettronica
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1 - Piston rings
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❑ Offset gaps by 120°
cop Vo
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❑ Use piston ring pliers to
Prote AG.
remove and install.

❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 40 .
❑ Checking ring-to-groove
clearance ⇒ page 40 .
2 - Piston
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 39 .
❑ Arrow on piston crown
points end of block.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Fitting position
⇒ page 39
❑ Piston and cylinder di‐
mensions ⇒ page 41 .
❑ Checking cylinder bores
⇒ page 40 .
3 - Piston pin
❑ If difficult to remove,
heat piston to 60°C.
❑ Remove and install using drift - VW 222 A- .
4. Pistons and conrods 37

4 - Retaining ring
5 - Connecting rod
❑ Renew as set only.
❑ Mark with cylinder number -A-.
❑ Installation position: Marking -B- faces towards front
6 - Bearing shell
❑ Observe installation position
❑ Upper bearing shell (towards piston) made of a more wear resistant material.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Ensure firm seating
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm. Do not turn crankshaft when measuring
radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 40 .
❑ Piston and cylinder dimensions ⇒ page 41 .
satelettronica
8 - Conrod bearing cap
9 - Oil spray jet
AG. Volkswagen AG d
❑ For piston cooling agen oes
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❑ When installing, turn oil spray jet clockwise onto limit
s ed b stop in cylinder block and tighten in
arathis position.
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10 - Bolt aut or
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❑ Insert without sealant.
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❑ 25 Nm
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11 - Conrod bolt
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❑ Oil threads and contact surface
hole
spec
❑ Use old bolt for measuring radial clearance.
es, in part or in w
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❑ Initial tightening torque: 5 Nm
❑ 30 Nm +90°
rrectness of i
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c
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4.2 Installation position and allocation of

wage
piston
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Piston installation
tho
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Pistonssin cylinders 1 and 2:
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Larger inlet valve recess -arrows- towards flywheel
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Piston in cylinders 3, 4 and 5:
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Larger inlet valve chamber -arrows- towards front
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Note
t to the co
♦ New piston allocation to cylinders is shown by a coloured
marking on piston crown.
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♦ Piston for cylinders 1 and 2: marked 1/2
l purpos
♦ Piston for cylinders 3, 4 and 5: Marking 3/4/5
nform
mercia
4.3 Measuring piston projection at TDC
satelettronica
a
com
tion in
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s
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♦ Measuring tool - VW 382/7-

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♦ Universal measuring tool - VW 385/17-
Without illustration:
♦ Dial gauge
Test sequence
Check piston projection at TDC when installing new pistons or a
short engine.
Depending on piston projection, fit the appropriate cylinder head
gasket according to following table.

Transporter 2004 ➤ AG. Volkswagen AG d
5-cylinder diesel engine - Edition 03.2018 agen oes
olksw not
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Piston projection ut
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s a c
0.51 mm … 0.66 mm s 1
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nl
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0.66 mm … 0.72 mm 2
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0.72 mm … 0.82 mm 3
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4.4 Checking piston ring gap hole
spec
es, in part or in w
t to the co
Checking piston ring gap
– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
rrectness of i
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Piston ring New Wear limit

dimensions in mm
nf
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1st compression ring 0.25 … 0.40 1.0
orm
2nd compression ring 0.30 … 0.50 1.0
m
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Oil scraper ring 0.25 … 0.50 1.0
or c
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4.5 Checking ring-to-groove clearance
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Checking ring-to-groove clearance
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Clean annular groove before check. rig ht
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Piston ring New Wear limit
agen
Prote AG.
dimensions in mm
1st compression ring 0.09 … 0.13 0.25
2nd compression ring 0.04 … 0.08 0.25
Oil scraper ring 0.03 … 0.07 0.15
4.6 Checking cylinder bores

Checking cylinder bores

♦ Internal dial test indicator 50 to 100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.08 mm

4.7 Piston and cylinder dimensions

No repairs designated.
Piston ∅ Cylinder bore ∅ AG. Volkswagen AG d
agen oes
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Basic dimen‐ mm 80.97 81.01 by Vol not
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15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 42
⇒ “1.2 Removing and installing cylinder head”, page 46
⇒ “1.3 Checking valve timing”, page 49
⇒ “1.4 Checking compression”, page 50
1.1 Assembly overview - cylinder head

⇒ “1.1.1 Assembly overview - cylinder head, engine codes AXD,
AXE and BLJ”, page 42
⇒ “1.1.2 Assembly overview - cylinder head, engine codes BNZ
and BPC”, page 44
1.1.1 Assembly overview - cylinder head, en‐

gine codes AXD, AXE and BLJ
satelettronica
Note
♦ When installing an exchange cylinder head with fitted cam‐

shaft, the contact surfaces between the bucket tappets and
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
lkswage es n
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Prote AG.
Rep. gr.15 - Cylinder head, valve gear
1 - Bleeder hose
❑ To air filter
2 - Pressure regulating valve
❑ For crankcase ventila‐
tion.
3 - Seal
5 - Bolt
❑ 15 Nm
6 - Cylinder head cover
❑ Before fitting, thorough‐
ly clean sealing surface
of cylinder head with
clean cloth. n AG. Volkswagen AG do
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7 - Cylinder head bolts aut or
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⇒ page 46
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8 - Bolt
spec
es, in part or in w
❑ 20 Nm
t to the co
9 - Tandem pump
❑ For fuel and vacuum
rrectness of i
supply
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⇒ Rep. gr. 20 ; Fuel
pump
nform
ercia
10 - Bolts
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i
❑ 10 Nm
on
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11 - Hall sender - G40-

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ate
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❑ For camshaft position.

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12 - O-ring
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13 - Seal cop Vo
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14 - Lifting eye
❑ With retainer for connector.
15 - Bolt
❑ 20 Nm
16 - Bracket
17 - Cylinder head gasket
❑ Imprint must be legible.
❑ Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When re‐
placing the cylinder head gasket, install a new gasket with the same identification (note number of holes
on right next to part number).
1. Cylinder head 43
18 - Bolt
❑ 20 Nm
19 - Bracket
20 - Coolant temperature sender - G62-
21 - Seal
❑ No replacement part
❑ Renew with ⇒ Item 22 (page 44)
22 - Plug
❑ With seal
23 - Cap
24 - Cylinder head
satelettronica
25 - Pipe connection
❑ Drive pipe connection in until stop
❑ Renewing ⇒ page 94
26 - Stud AG. Volkswagen AG d
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❑ 14 Nm olksw not
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28 - Lifting eye
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Checking cylinder head for distortion
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Max. permissible distortion: 0.1 mm
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Note
Reworking diesel cylinder heads is not permissible. rrectness of i

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1.1.2 Assembly overview - cylinder head, en‐

or
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♦ When installing an exchange cylinder head with fitted cam‐
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shaft, the contact surfaces between the bucket tappets and Prote AG.
the cam must be oiled before installing the cylinder head cov‐
er.
♦ The plastic protectors fitted to protect the open valves must
only be removed immediately before fitting the cylinder head.
44 Rep. gr.15 - Cylinder head, valve gear

2 - Bolt
❑ 15 Nm
3 - Cylinder head cover
❑ Before fitting, thorough‐
ly clean sealing surface
of cylinder head with
clean cloth.
4 - Cylinder head bolts
❑ Qty. 12
⇒ page 46
5 - Bolts
❑ 20 Nm
6 - Tandem pump
❑ For fuel and vacuum
satelettronica
supply
⇒ Rep. gr. 20 ; Fuel
pump
7 - Bolts
❑ 10 Nm
8 - Hall sender - G40- AG. Volkswagen AG d
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❑ For camshaft position. olksw
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9 - O-ring orise nte
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10 - Seal
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11 - Lifting eye
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❑ With retainer for connector.
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12 - Bolt
spec
❑ 20 Nm t to the co
13 - Bracket
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14 - Cylinder head gasket

ss
❑ Imprint must be legible.

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❑ Different thicknesses of cylinder head gasket are fitted depending on the piston projection. When re‐
nform
placing the cylinder head gasket, install a new gasket with the same identification (note number of holes
mer
on right next to part number).

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15 - Bolt
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❑ 20 Nm
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16 - Bracket
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17 - Coolant temperature sender - G62- Cop py
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18 - Seal
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1. Cylinder head 45
19 - Plug
❑ With seal
20 - Cap
21 - Cylinder head
22 - Pipe connection
❑ Drive pipe connection in until stop
23 - Stud
❑ 14 Nm
24 - Lifting eye
25 - Bolts
❑ 20 Nm
satelettronica
26 - Seal
27 - Bleeder hose
28 - Buffer stop wage
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Checking cylinder head for distortion
aut or
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Max. permissible distortion: 0.1 mm
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Note
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Reworking diesel cylinder heads is not permissible.

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1.2 Removing and installing cylinder head

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♦ Hexagon bit, long reach - T10061-

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Removing
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Prote AG.
– Move lock carrier into service position: ⇒ General body re‐
pairs, exterior; Rep. gr. 50 ; Body - front; Lock carrier - service
position .

– Remove charge air pipes between charge air cooler/turbo‐

charger and charge air cooler/intake connecting pipe.
– Remove intake manifold ⇒ page 126 .
– Remove exhaust gas recirculation connecting pipe.
– Remove engine cover panel and cylinder head cover
⇒ Item 6 (page 43) .
Note
Only both bolts to cylinder head must be removed.
– Remove securing bolts of valve timing housing cover to cylin‐

der head ⇒ page 26 . n AG. Volkswagen A ge G do
swa es n
– Remove tandem pump ⇒ Rep. gr. 20 ; Fuel pump
by
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– Unscrew turbocharger/exhaust manifold securing
ho
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ut or
⇒ page 100 . ss
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– Disconnect all necessary coolant and vacuum hoses as well

nl
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as electrical connections on cylinder head.
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– Remove upper coolant pipe.
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– Turn engine to TDC no. 1 cylinder ⇒ page 49 .
, is n
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– Remove camshaft drive gear ⇒ page 57 .
spec
es, in part or in w
– Observe correct sequence when loosening cylinder head
t to the co
bolts.
rrectness of i
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1. Cylinder head 47
Installing
Install in reverse order of removal, observing
olks
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Note aut or
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♦ Do not use sandpaper, grinding wheels, abrasive or scour le
un
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pads or any other sanding or abrasive media.

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♦ Sealing surface (see photo) must not project.
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♦ Discolouration (dark spots, see photo) need not be removed.
h re
hole
spec
♦ When removing the sealant residue, make sure no loose par‐
es, in part or in w
ticles get into the open channels of the engine.
t to the co
♦ Ensure that all adjacent workspaces are clean, and that none
of the above mentioned sanding or abrasive media are used.
rrectness of i
♦ Using unauthorised sanding or abrasive media may lead to
l purpos
secondary damage such as, for example, damage to the tur‐

bocharger or the conrod bearings.
nform
ercia
satelettronica
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WARNING
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tion in
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Wear protective goggles.
thi
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– Do not use any other means rather than the contour blade set
n
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- VAS 852 005- or a commercially available CERAN surface Cop py
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scraper to remove the sealant residue from the cylinder head
t
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and cylinder block. cop Vo
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• The sealing surfaces must not be damaged.
AG.
• There must be no oil or coolant in the bolt pockets.

• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between
roller rocker fingers and running surface of cam must be oiled.
– Remove any loose remains using a lint-free cloth.
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐

pending on the piston projection. When replacing the cylinder
head gasket, install a new gasket with the same identification
(note number of holes on right next to part number).
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
– Position cylinder head gasket.

– Fit cylinder head, install cylinder head bolts and tighten hand
tight.

– Tighten cylinder head in 6 stages in sequence shown as fol‐

lows:
– Tighten initially with torque wrench:
Stage I = 60 Nm
– Turn further with rigid spanner:
Stage II = 1/4 turn (90°)
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Stage V = 1/4 turn (90°)

– Turning back with rigid spanner:
Stage VI = loosen all cylinder head bolts 1/4 turn (90°).
– Install camshaft drive gear ⇒ page 57 .
– Screw turbocharger tight ⇒ page 100 .
satelettronica
– Install charge air pipes between charge air cooler/turbocharg‐
er and charge air cooler/intake connecting pipe.
– Install intake manifold.
– Install exhaust gas recirculation connecting pipe.
– Install cylinder head cover and engine cover panel
– Carry out road test and readn all
AG.event memories
Volkswagen AG ⇒ Vehicle
diagnostic tester. olkswage does
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1.3 Checking valve timing
r
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♦ Camshaft clamp - T10193-

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♦ Crankshaft clamp - T10226-

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spec
♦ Removal tool - VW 681-

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♦ Extractor hook - 10-221-

rrectne
With engine installed
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– Remove air filter ⇒ page 129 .

inform
mer

atio
om
– Remove front right wheel.

n
c
i
or
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– Remove front right wheel housing liner ⇒ General body re‐

t
sd
va
pairs, exterior; Rep. gr. 66 ; Removing and installing wheel

i
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housing liners .
fo
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– Release lower coolant pipe. Cop py
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Do not drain coolant. p by
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Prote AG.
1. Cylinder head 49
AG. Volkswagen AG d
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Transporter 2004 ➤ autho eo
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5-cylinder diesel engine - Edition 03.2018 ss c
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Continuation with engine removed or in situ
itte
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– Remove camshaft cover -arrow- using oil seal extractor lever
ility
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- VW 681- .
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
– Unscrew securing bolt -arrow- from engine support.

m
at
om
– Remove sealing cover from face of sealing flange using ex‐
ion
c
tractor hook - 10-221- .
in t
or
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ate
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Cop py
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rig
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Prote AG.
Note
It is only possible to bolt special wrench - T10225- onto crankshaft

in one position.
– Turn crankshaft in direction of engine rotation until marks

-arrows- on special wrench - T10225- and sealing flange align.
– Unbolt special wrench - T10225- from crankshaft.
– Secure crankshaft with crankshaft clamp - T10226- as shown.

At the same time, the crankshaft locking piece must engage
(through the engine bracket) in the cylinder block.
– Bolt crankshaft clamp - T10226- onto crankshaft.
Note
♦ It is only possible to bolt crankshaft clamp - T10226- onto

crankshaft in one position.
♦ If the crankshaft clamp cannot be secured, turn the crankshaft
one revolution further in the direction of engine rotation until
the marks on the special wrench - T10225- and sealing flange
align again.
– Fit camshaft clamp - T10193- .

– Check position of camshaft sprocket ⇒ page 57 .
1.4 Checking compression


equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
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♦ U/J extension and socket,
uthor
10 mm - 3220- eo
ra
s a c
♦ Torque wrench - V.A.G
s 1331- (5 to 50 Nm)
ce
le
un
pt
♦ Adapter - V.A.G 1381/12-

an
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♦ Compression tester - V.A.G 1763-

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ility
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Prerequisites for check

, is n
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• Engine oil temperature min. 30°C

spec
es, in part or in w
Test sequence
t to the co
– Bring lock carrier into service position ⇒ General body repairs,

exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
rrectness of i
sition .
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– Detach central connector from unit injectors.
nform
ercia
– Remove glow plugs ⇒ page 154 .

m
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tion in
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Prote
cted AG.
agen 1. Cylinder head
Note
♦ Always observe notes on removing and installing ceramic

glow plugs ⇒ page 154 .
♦ Using the compression tester ⇒ Operating instructions
– Screw in adapter - V.A.G 1381/12- in place of the glow plugs.

– Check compression using compression tester - V.A.G 1763- .
– Operate starter until tester shows no further pressure in‐
crease. AG. Volkswagen AG d
agen oes
lksw not
Compression pressures: d byV
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New: 25 … 31 bar, wear limit: 19 bar ut
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Permissible difference between all cylinders: 5 bar s
ce
le
un
pt
– Install all glow plugs using U/J extension and socket, 10 mm
an
d
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- 3220- .
rm
ab
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satelettronica
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Note
h re
hole
spec
es, in part or in w
Disconnecting the central connector for unit injectors causes
t to the co
faults to be stored. Therefore, read event memory and delete if
necessary.
rrectness of i
– Read event memory ⇒ Vehicle diagnostic tester.
l purpos
Specified torques
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 126
nform
mercia
a
com
tion in
r
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thi
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t.
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Cop py
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rig ht
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Prote AG.

2 Valve gear
⇒ “2.1 Assembly overview - valve gear”, page 53
⇒ “2.2 Measuring axial play of camshaft”, page 55
⇒ “2.3 Removing and installing camshaft”, page 56
⇒ “2.4 Removing and installing camshaft drive gear”, page 57
⇒ “2.5 Removing and installing valve stem seals”, page 61
2.1 Assembly overview - valve gear
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and no
more than 0.5 mm wide.
AG. Volkswagen AG d
agen oes
1 - Bolt Vol
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❑ Renew ris after removal
ed
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❑ s8a Nm +90°
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⇒ page 56 .
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❑ 20 Nm +90°
spec
es, in part or in w
3 - Rocker arm shaft

t to the co
❑ Do not interchange
4 - Bucket tappet
rrectness of i
❑ Do not interchange
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❑ With hydraulic valve

clearance compensa‐
nf
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tion.
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❑ Set down with contact

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surface facing down‐

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❑ Oil contact surface

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❑ Before installing, check

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camshaft axial clear‐

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op
ance ⇒ page 55 . C py
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5 - Cotters
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6 - Valve spring plate
Prote AG.
7 - Outer valve spring

❑ Removing and instal‐
ling, with cylinder head
removed: use valve
spring compressor -
2037- , with installed
⇒ page 61 .
8 - Inner valve spring
❑ Removing and installing, with cylinder head removed: use valve spring compressor - 2037- , with installed
⇒ page 61 .
2. Valve gear 53
9 - Valve stem seal

❑ Renewing ⇒ page 61 agen
AG. Volkswagen AG d
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10 - Washer ed byV gu
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❑ For cylinder head bolts. ut
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❑ Insert in cylinder head before installing bearing
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11 - Valves
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❑ Valve dimensions ⇒ page 66
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❑ Reworking valve seats ⇒ page 64 .
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❑ Checking valve guides ⇒ page 65
h re
hole
spec
12 - Unit injector
es, in part or in w
t to the co
13 - Cylinder head
❑ Observe notes ⇒ page 53
rrectness of i
❑ Reworking valve seats ⇒ page 64 .
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nform
ercia
14 - Eccentric pin
satelettronica
❑ Oil when installing.
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❑ Note installation position ⇒ page 57 .
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15 - Bolt
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❑ 20 Nm +90°
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Cop py
16 - O-ring ht. rig
rig ht
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❑ Renew after removal co Vo
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17 - Bolt
❑ 10 Nm
18 - Cap
19 - Washer
20 - Compensating link plate
21 - Drive gear
❑ For camshaft.
22 - Guide sleeve
23 - Bolt
❑ 150 Nm +90°
24 - Tandem pump shaft
❑ Checking tandem pump ⇒ Rep. gr. 20 ; Fuel pump
❑ Removing and installing tandem pump ⇒ Rep. gr. 20 ; Fuel pump
25 - Camshaft sprocket
❑ With camshaft position sender wheel.
26 - Washer (diamond-coated)

27 - Bearing shell
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
28 - Camshaft
❑ Check radial clearance with Plastigage, wear limit: 0.11 mm
❑ Runout: max. 0.01 mm
❑ Identification and valve timing ⇒ page 55 .
❑ Checking axial clearance ⇒ page 55 .
29 - Bearing cap
❑ Seal parting surfaces of outer bearing caps with silicone sealant - D 176 501 A1- ⇒ page 55
Sealing parting surfaces of bearing caps 1 and 7 with silicone

sealant - D 176 501 A1-
– Apply thin, even coat of silicone adhesive sealant - D 176 501
A1- to sealing surface.
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Camshaft identification, valve timing

h re
hole
spec
Identification
es, in part or in w
t to the co
♦ Cam base diameter: a = 52.8 mm ∅.

♦ Identification by stamped numbers and letters on drive-end
face of camshaft.
rrectness of i
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Drive end -arrow- 070 M

Valve timing at 1 mm opening lift
nform
ercia
Inlet opens ATDC 12°

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Inlet closes ABDC 21.5°

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or
Exhaust opens BBDC 30°

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Exhaust closes BTDC 20.5°

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en
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2.2 Measuring axial play of camshaft
C py
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Prote AG.
♦ Dial gauge
Checking camshaft axial clearance
Check with bucket tappets removed and with 2, 4 and 6 bearing
caps fitted.
Wear limit: max. 0.15 mm
2. Valve gear 55
2.3 Removing and installing camshaft

♦ Silicone adhesive sealant - D 176 501 A1-
Removing
. Volkswagen AG
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– Remove charge air pipes between
Vol
ksw charge air cooler/turbo‐
oes
not
gu
charger and charge airedcooler/intake connecting pipe.
by ara
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or
– Remove intake manifold
au
th support. or
ac
ss
ce
e
nl
pt
du
an
– Remove intake manifold ⇒ Item 5 (page 126) .
itte
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⇒ page 42 .
wit
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– Remove tandem pump ⇒ Rep. gr. 20 ; Fuel pump .
hole
spec
es, in part or in w
– Remove camshaft drive gear ⇒ page 57 .
t to the co
satelettronica
– Remove rocker arm shafts ⇒ page 114 .
– Loosen bearing caps from outside to inside, loosening bolts of
rrectness of i
last two bearing caps alternately and diagonally.
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Installing
Install in reverse order of removal, observing the following: nf
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Note
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♦ Ensure that no valve is pressed against a piston during instal‐

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lation of the camshaft. Position pistons as uniformly as possi‐

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♦ When installing the camshaft, ensure proper seating of retain‐
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♦ Before installing bearing caps, ensure that cylinder head bolt

washers are inserted in the cylinder head.
♦ Seal parting surfaces of outer bearing caps with silicone seal‐
ant - D 176 501 A1- ⇒ page 55
– Oil running surfaces of shell bearings.

– Tighten 2 inner bearing caps alternately and diagonally.
– Install remaining bearing caps, and tighten them.
– Install rocker arm shaft. By hand, first tighten inner and then
outer bolts evenly and diagonally. Tighten in same sequence.
– Re-install camshaft drive gear ⇒ page 57 .
– Install tandem pump ⇒ Rep. gr. 20 ; Fuel pump .
⇒ page 42 .
– Install intake manifold support.

Note
When new bucket tappets have been installed the engine must
not be started for about 30 minutes. The hydraulic compensation
elements must settle (otherwise valves will strike pistons).
Specified torques
♦ ⇒ “2.1 Assembly overview - valve gear”, page 53
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 42
2.4 Removing and installing camshaft drive

gear
♦ Clamp - T10199-
♦ Press tool - T10199/1-
satelettronica
♦ Insert tool - T10234-
♦ Torque wrench - V.A.G 1331- lkswage es n
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♦ Torque wrench - V.A.G 1332- o
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♦ Torque wrench - VAS 6253- ss
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Removing
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– Set engine to TDC no. 1 cylinder ⇒ page 49 .
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– Remove charge air pipes between charge air cooler/turbo‐
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charger and charge air cooler/intake connecting pipe.
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spec
– Remove intake manifold support.
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rrectne
– Remove tandem pump ⇒ Rep. gr. 20 ; Fuel pump . ss
– Detach central connector of unit injectors and release con‐
o
cial p
nector on cylinder head using wrench - T10211-

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2. Valve gear 57
Transporter 2004 ➤ AG. Volkswagen AG d
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– Remove outer bearing cap t-A-.
oris Mount clamping device - eo
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T10199- on camshaft sprocket
ss
au and tighten its bolts to 40 Nm. ra
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– Loosen camshaft sprocket securing bolt -B- using XZN 16 bit
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- T10198- and unscrew together with tandem pump shaft.
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– Remove camshaft sprocket from camshaft.
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– Remove Hall sender - G40- -C- for camshaft position.
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– Unscrew cap from eccentric pin.
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– Loosen securing bolt -D- and withdraw eccentric pin.
t to the co
– Carefully remove camshaft drive gear together with balancer
plate.
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Installing
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Caution
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The engine can be damaged.

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When installing a diamond-coated washer which has already

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been used, the drive pulley cannot be properly secured to the
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Use new diamond-coated washer!
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– Lubricate entire surface of guide sleeve -4-.

– Mount camshaft drive gear -3- on guide sleeve.
– Fit washer -2- as shown.
Note
The lugs of the disc must engage in the grooves of the guide
sleeve
– Mount camshaft drive gear with washer and guide sleeve on

balancer plate -1-.
Note
The marks -A- on the guide sleeve and the balancer plate must
align.

– Carefully insert balancer plate with camshaft drive gear from

top into gear chamber.
– Lubricate entire surface of eccentric pin. -5-.
– Install eccentric pin. The marking -B- on the eccentric pin must
be vertical and uppermost.
Note
Marking -C- must align with sealing surface of cylinder head.
satelettronica
– Install outer bearing cap and tighten hand tight.
– Install new securing bolt -6- for eccentric pin and tighten by
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hand until approx. one turn before limit stop.
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– Locate insert tool - T10234- withristorque
ed wrench - VAS 6253- ara
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in eccentric pin holes. ut
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2. Valve gear 59
– Carefully turn eccentric pin anticlockwise to 50 Ncm (0.5 Nm).

– Hold eccentric pin in this position and tighten new eccentric
pin securing bolt.
– Remove outer bearing cap again.
– Place central connector of unit injectors carefully into cylinder
head.
– Install outer bearing cap with sealant and tighten using new
bolts.
Note
Seal parting surfaces of outer bearing caps with silicone sealant

- D 176 501 A1- ⇒ page 55
– Lock central connector using wrench - T10211- .

– Screw caps of eccentric pin and Hall sender - G40- tight.
Note
satelettronica
♦ Check that the washer is seated correctly on the camshaft be‐
fore installing the camshaft sprocket.
♦ The teeth of the gear wheel must be oiled completely.
– Locate camshaft sprocket on camshaft such that marking on

sender wheel -arrow- aligns with upper edge of cylinder head
sealing surface. gen AG
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– Secure camshaft gear wheel and tandem pump db
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– Locate clamping tool - T10199/1- as shown and tighten clamp‐

es, in part or in w
t to the co
ing bolts to 70 Nm.

– Fit torque wrench - V.A.G 1332- into square drive of clamping
tool and exert force of 80 Nm counter to direction of engine
rrectness of i
rotation to remove play from gear train.

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– Maintain specified force and tighten camshaft sprocket secur‐

ing bolt -A- to torque of 50 Nm using XZN 16 bit - T10198- .
nform
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– Remove clamping tool - T10199/1- .

– Place clamping device - T10199 - on camshaft sprocket.
Note
Ensure the clamp - T10199- lies flush with the cylinder head.
– Tighten bolts of clamping device - T10199- to 40 Nm.

– Then secure camshaft gear wheel using socket XZN 16 -
T10198- .
– Remove clamping device - T10199- .
– Remove clamps from camshaft and crankshaft.
– Install tandem pump ⇒ Rep. gr. 20 ; Fuel pump .
– Turn crankshaft two revolutions further in direction of engine
rotation until crankshaft is again set to TDC no. 1 cylinder.
satelettronica
– Check that camshaft and crankshaft clamps can be inserted.
– Fit new sealing cover for camshaft.
– Fit new sealing cover for crankshaft.
– Install intake manifold support.
Specified torques n AG. Volkswagen AG do
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♦ ⇒ “1.1 Assembly overview - cylinder head”,
uth page 42
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2.5 Removing and installing valve stem seals

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2. Valve gear 61
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Transporter 2004 ➤ ho
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♦ Valve assembly device - 2036-

♦ Puller - 3047A-
♦ Thrust piece - 3129-
♦ Assembly lever - VW 541/1A-
♦ Press tool - VW 541/5-
Removing
(With cylinder head installed)
– Remove camshaft ⇒ page 56 .
– Remove tappets and place to one side with face downwards.
When doing this, ensure that tappets are not interchanged.
– Set piston of respective cylinder to top dead centre (TDC).

– Fit valve assembly tool - 2036- and adjust mountings to height

of studs.
– Remove valve springs using valve lever - VW 541/1A- and
press tool - VW 541/5- .
Note
The valves are supported by the piston crown.
– Pull off valve stem seals using puller - 3047 A- .

Installing
satelettronica
– Place the plastic sleeve -A- supplied on the associated valve
stem. This will prevent the new valve stem seal -B- being
damaged.
– Place new valve stem seal in fitting tool
wage
- .3129-
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– Oil valve stem seal sealing d lip
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2. Valve gear 63
3 Inlet and exhaust valves

⇒ “3.1 Reworking valve seats”, page 64
⇒ “3.2 Checking valve guides”, page 65
Volkswagen AG
⇒ “3.3 Valve dimensions”, page 66swagen AG. does
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3.1 Reworking valve seats ris
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Special tools and workshop equipment au required
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♦ Depth gauge
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♦ Valve seat refacing tool
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Note
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♦ When repairing engines with leaking valves, it is not sufficient
t to the co
to rework or renew valve seats and valves. There is also a
requirement to check the valve guides for wear. This is par‐
ticularly important on high mileage engines.
rrectness of i
satelettronica
♦ Valve seats are only to be reworked to the extent required to
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yield a proper surface appearance. Before reworking the valve

seats, calculate the maximum permissible reworking dimen‐
sions. If the reworking dimension is exceeded, the hydraulic
nform
ercia
valve clearance compensation can no longer be guaranteed

and the cylinder head must be renewed.
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The max. permissible reworking dimension is calculated as fol‐

thi
s
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lows:
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– Insert valve and press firmly against seat.

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If the valve is to be renewed as part of a repair, use a new valve
for the calculation.
– Measure distance -a- between end of valve stem and upper

edge of cylinder head.
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
Minimum dimension:
Inlet valve: 43.4 mm
Exhaust valve: 43.2 mm
Measured distance minus minimum dimension = max. permissi‐
ble reworking dimension.
Example:
Measured distance 44.1 mm
- Minimum dimension 43.4 mm
= Max. permissible reworking dimension 0.7 mm

n AG. Volkswagen AG do Transporter 2004 ➤
lkswage es n
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5-cylinder
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Reworking inlet valve seat:
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a = ∅ 35.7 mm
nl
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b = 1.6 mm
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45° = Valve seat angle
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Note
spec
es, in part or in w
t to the co
The 30° lower valve seat chamfer is necessary to ensure that the
inlet channel flow characteristics are maintained.
rrectness of i
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Reworking exhaust valve seat:
nf
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a = ∅ 31.4 mm
b = 2.7 mm
45° = Valve seat angle
3.2 Checking valve guides

♦ Dial gauge
3. Inlet and exhaust valves 65

Test sequence
– Insert new valve in guide. The end of the valve stem must be
flush with the guide. On account of differing stem diameters,
only use inlet valve in inlet guide and exhaust valve in exhaust
guide.
– Rock: max. 1.3 mm
– Cylinder head must be renewed if rock exceeds wear limit.
3.3 Valve dimensions

Valve dimensions
Note
satelettronica
Do not rework valves. Only lapping-in is permitted.
AG. Volkswagen AG d
Dimension Inlet valve Outlet valve
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∅a mm 35.95 ir s31.45
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∅b mm 6.980 aut 6.956 ra
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α ∠° 45 45
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17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 67
⇒ “1.2 Removing and installing oil sump”, page 68
⇒ “1.3 Engine oil:”, page 70
1.1 Assembly overview - sump/oil pump
1 - Bolt
❑ 20 Nm
2 - Oil dipstick
❑ The oil level must not be
above the max. mark
❑ Markings ⇒ page 70 .
satelettronica
3 - Guide tube
4 - Cap
5 - Seal
6 - Boot
❑ Renew if damaged agen
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7 - Oil filler tube d by ara
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8 - Bolt auth
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❑ 10 Nm ce
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9 - Seal an
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10 - Oil spray jet
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❑ For piston cooling

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11 - Bolt
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❑ Insert without sealant.

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❑ 25 Nm
12 - Dowel sleeves
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13 - Oil pump
s

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that both dowel sleeves

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for centring oil pump on

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14 - Seal
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15 - Suction hose
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❑ Clean strainer if soiled yi

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16 - Oil pan
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❑ Clean sealing surface before fitting. cop Vo
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❑ Install with silicone sealant ⇒ Electronic parts catalogue (ETKA) . Prote AG.

17 - Bolt
❑ 15 Nm
1. Sump, oil pump 67

18 - Oil drain plug

❑ 30 Nm
19 - Seal
20 - Oil level and oil temperature sender - G266-
❑ Not installed on all engines.
21 - Bolt
❑ 15 Nm
22 - Oil filter housing
❑ With engine oil cooler.
❑ Assembly overview ⇒ page 71
23 - Bolt
❑ 20 Nm
24 - Seal
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25 - Baffle plate ed by ara
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26 - O-ring tho eo
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1.2 Removing and installing oil sump

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♦ Hand drill with plastic brush attachment

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♦ Scraper
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Note
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Silicone sealant ⇒ Electronic parts catalogue (ETKA)

nform
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Removing
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– Unscrew coolant pipe from sump.

s
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– Loosen subframe ⇒ Running gear, axles, steering; Rep. gr.

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40 ; Removing and installing subframe and lower to floor.

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– Remove bevel box ⇒ 0A5 6-speed manual gearbox, all -wheel
op Vo
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– Detach oil level and oil temperature sender - G266- , if fitted.
– Remove gearbox noise insulation.
– Drain engine oil.
– Unbolt sump.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
68 Rep. gr.17 - Lubrication

Installing
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove sealant residues on sump with rotating brush, e.g.
hand drill with plastic brush insert (wear safety goggles).
– Clean sealing surfaces.
They must be free of oil and grease.
Note
♦ Check the expiry date of the sealant.

♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

3 mm).
satelettronica
– Apply silicone sealant to clean sealing surface of sump as
shown. Sealant bead must be:
♦ 2 … 3 mm thick.
♦ run along inner side of bolt holes -Arrows-
Note
♦ The sealant bead must not be thicker, otherwise excessive

sealant may enter the sump and block the oil suction pipe
strainer.
♦ The sump must be flush with cylinder block.
AG. Volkswagen AG d
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– Apply silicone sealing compound d b bead as shown to the clean
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– Immediately position sump
ss and tighten all sump bolts slightly. c
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– Tighten sump bolts.

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– Tighten bolts between sump and gearbox.

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Note
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Allow sealing compound to dry for approx. 30 minutes after in‐

t to the co
stalling sump. Only then fill with engine oil.

rrectness of i
Specified torques
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♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 67

Specified torques
nform
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Bolts between sump and gear‐ 45 Nm

on in
box.
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Prote AG. 1. Sump, oil pump
AG. Volkswagen AG d
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1.3 Engine oil: by
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The oil level must remain below the max. mark - danger of dam‐
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age to catalytic converter! Markings ⇒ page 70 .
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Oil capacities:
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Without oil filter: 7.0 l; with oil filter: 7.4 l
spec
es, in part or in w
Engine oil specification ⇒ Maintenance ; Booklet 19.1
t to the co
Markings on oil dipstick
rrectness of i
1 - Max. mark
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2 - Min. mark
a - Area above hatched field up to max. mark: Do not top up with
nform
ercia
engine oil!
m
b - Oil level within hatched field: Can be topped up with engine
at
om
io
oil.
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c - Area from min. mark up to hatched field: top up with max. 0.5 l
at
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2 Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter housing”, page 71
⇒ “2.2 Removing and installing oil filter housing”, page 72
⇒ “2.3 Checking oil pressure and oil pressure switch”,
page 74
⇒ “2.4 Measuring oil consumption”, page 76
2.1 Assembly overview - oil filter housing
WARNING
When working in the area of the engine oil cooler, it is essential

to disconnect the earth strap from the battery (with ignition
switched off) to prevent a short circuit at the alternator through
tools used for repairs.
♦
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1 - Engine oil cooler tho tee
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❑ To remove, the housing ss
-12- must be removed.
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2 - Bolt
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❑ 10 Nm
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3 - Coolant hose
h re
hole
❑ Connection diagram for
spec
coolant hoses
es, in part or in w
t to the co
⇒ page 77
4 - Bracket
rrectness of i
5 - Bolt
l purpos
❑ 10 Nm
6 - Threaded cover
nform
ercia
❑ 25 Nm
m
at
7 - Seal
om
ion
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❑ Renew after removal in t

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8 - Oil filters
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9 - O-ring
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❑ Renew after removal C py
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10 - Oil pressure switch - F1-
p by
co Vo
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cted
❑ 0.9 bar
agen
Prote AG.
❑ If seal is leaking, nip

open and renew.
❑ Checking ⇒ page 74
❑ 25 Nm
11 - Bolt
❑ 20 Nm
12 - Housing
❑ To remove, the air conditioner compressor must be unscrewed and detached, the lines remain connec‐
ted.
❑ Removing ⇒ page 72
2. Oil filter, oil pressure switch 71

13 - Seal
wage
14 - Seal olks es n
ot g
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❑ Renew if damaged ir se
d ran
tee
tho
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a ac
ss
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le
un
2.2 Removing and installing oil filter housing
pt
an
d
itte
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ab
pe
ility
ot
wit
♦ Torque wrench - V.A.G 1331- (5 … 50 mm)
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nform
mercia
a
com
tion in
r
te o
thi
♦ Guide pins - T10228-
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Removing
WARNING
When working in the area of the engine oil cooler, it is essential

to disconnect the earth strap from the battery (with ignition
switched off) to prevent a short circuit at the alternator through
tools used for repairs.
♦
– Drain engine oil.

sition .
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Removing and installing air conditioner
compressor .

The refrigerant lines remain connected to air conditioner com‐

pressor.
– Secure air conditioner compressor to body using a suitable
item, e.g. welding wire.
When doing this, ensure that the coolant hoses on the air condi‐
tioner compressor are not under stress.
– Unscrew bolts -arrows- and remove bracket -1-.
satelettronica
– Unscrew bolt -1- and remove coolant hose bracket -2-.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
– Unplug connector -1- from oil pressure switch - F1- .

pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
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t.
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Cop py
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pyri by
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73
cted agen
Prote
2. Oil filter, oil pressure switch
AG.
– Loosen clip -2- and pull off coolant hoses -1-.
– Unscrew bolts -1-.

– Remove oil filter housing upwards.
Installing
During this procedure, observe the following:
♦ Always install a new seal.
satelettronica
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
– Tighten bolt -1- for oil filter housing. t to the co

Specified torques
rrectness of i
♦ ⇒ “2.1 Assembly overview - oil filter housing”, page 71

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 Checking oil pressure and oil pressure switch


equipment required
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Oil pressure tester - V.A.G 1342-

♦ Voltage tester - V.A.G 1527B-
♦ Auxiliary measuring set - V.A.G 1594 A- or auxiliary measuring
set - V.A.G 1594C-
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
Test conditions
• Engine oil temperature min. 80°C
• Engine oil level OK.
Test sequence
sition .
– Loosen air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87
2. Oil filter, oil pressure switch 75

– Suspend air conditioner compressor such that lines and hoses

are not stretched, kinked or bent or cannot contact the radiator
fan.
– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter housing in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594 A- or auxiliary measuring set - V.A.G 1594C- .
LED must not light up.
Rep. gr. 87 . n AG. Volkswagen AG do
lkswage es n
o ot g
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– Start engine and increase revolutionsisslowly.
ed
b At 0.75 … 1.05 ran
bar, the LED must light up; otherwiseuth renew oil pressure
or tee
or
switch. ss
a ac
ce
le
– Increase engine speed further. At 2,000 rpm and an oil tem‐

un
pt
an
d
perature of 80°C; the oil pressure should be at least 2.0 bar.

itte
y li
erm
ab
satelettronica
At higher engine speeds, the oil pressure must not exceed 7.0
ility
ot p
bar.
wit
is n
h re
ole,
spec
2.4 Measuring oil consumption
t to the co
♦ Vehicle diagnostic tester
rrectne
s
– Apply handbrake.
s o
cial p
f i
– Manual gearbox: gear lever in neutral.
nform
mer
– Automatic gearbox: move selector lever to position “N”. atio

om
– Connect ⇒ Vehicle diagnostic tester.

c
i
or
n thi
te
sd
– Switch on ignition.
iva
o
pr
cum
r
– Carry out program “oil consumption measurement” using

fo
en
ng
⇒ Vehicle diagnostic tester.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 77
⇒ “1.2 Draining and adding coolant”, page 78
⇒ “1.3 Checking cooling system for leaks”, page 85
1.1 Connection diagram - coolant hoses
1 - Heat exchanger for heater

2 - Auxiliary water heater
❑ Not necessarily instal‐ lkswage es n
led d byV
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e ran
ris tee
3 - Additional heatuthexchanger
o
or
a ac
❑ Not necessarily
ss instal‐
ce
e
led
nl
satelettronica
pt
du
an
itte
4 - Circulation pump - V55-
y li
erm
ab
ility
5 - Upper coolant pipe
ot p
wit
, is n
6 - Radiator/cooler
h re
hole
spec
❑ For exhaust gas recircu‐
es, in part or in w
lation
❑ Only vehicles with auto‐ t to the co
matic gearbox.
rrectness of i
7 - Cylinder head/cylinder
block
l purpos
8 - Coolant expansion tank

nform
ercia
9 - Radiator/cooler
m
at
10 - Engine oil cooler

om
ion
c
in t
or
11 - Coolant pump
his
ate
do
riv
12 - Lower coolant pipe

p
cum
for
en
g
13 - Thermostat housing
n
t.
yi Co
Cop py
t. rig
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by
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Prote AG.
1. Cooling system/coolant 77
1.2 Draining and adding coolant

⇒ “1.2.1 Draining and adding coolant”, page 78
⇒ “1.2.2 Charging the cooling system in the case of emergency”,
page 83
1.2.1 Draining and adding coolant

equipment required
wage es n
satelettronica
olks ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
♦ Refractometer - T10007 A-
gh ht
pyri by
Vo
co lksw
by
♦ Spring-type clip pliers - V.A.G 1306- discontinued, use hose cted agen
Prote AG.
♦ Assembly tool for spring-type clip pliers - VAS 5024 A- dis‐
continued, use hose clip pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter - V.A.G 1274/8-
78 Rep. gr.19 - Cooling

Draining
WARNING
Hot steam may escape when expansion tank is opened. There‐

fore, cover sealing cap with a cloth and open it carefully.
– Open filler cap on coolant expansion tank.

– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Exterior equipment; Noise insulation .
– Detach coolant hose -1- from radiator in order to drain coolant.
Note
Follow disposal regulations for coolant!
Filling
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, always use only distilled
water when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant.
n AG. For
Volksthis
wagereason,
n AG d the cooling
system must be filled lkswage
all-year-round with coolant
oes
noadditives.
Vo
satelettronica
y tg ua
db r
♦ Because of its
or high boiling point, the coolant improves engine
ise an
tee
reliability under
au
th heavy loads, particularly in countries with trop‐
or
ac
ical climates.
ss
ce
le
un
pt
♦ The refractometer - T10007A- must be used to determine the

an
d
itte
current anti-freeze value.

y li
erm
ab
ility
♦ The coolant concentration must not be reduced by adding wa‐

ot p
wit
ter even in warmer seasons and in warmer countries. Frost

is n
h re
protection must be guaranteed down to at least -25°C.

ole,
spec
♦ Read off anti-freeze figures for respective replenished coolant

t to the co
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
rrectne
forming in the coolant below this temperature.

♦ Never reuse old coolant.
ss o
cial p
♦ Use only a water/coolant additive mixture as a slip agent for

inform
coolant hoses.
mer
atio
om
Coolant mixture ratio

c
i
or
n thi
te
• Coolant additive (40%) and water (60%) for frost protection to

sd
iva
o
r
-25°C
p
cum
r
fo
en
ng
• Coolant additive (50%) and water (50%) for frost protection to

t.
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op
-36°C C py
t. rig
gh ht
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• Coolant additive ⇒ Electronic parts catalogue
cop Vo
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Prote
– Push lower coolant hose onto radiator union and secure.
AG.

AG. Volkswagen AG 5-cylinder diesel engine - Edition 03.2018
agen does
olksw not
yV g
– Fill tank of cooling system charge db unit - VAS 6096- with at least uaran
ise
8 litres of pre-mixed coolantho
r in correct mixture ratio. tee
aut or
ac
ss
ce
e
nl
pt
Note
du
an
itte
y li
erm
ab
The quantity may vary depending on the equipment level.
ility
ot p
wit
, is n
h re
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
hole
coolant expansion tank -1-.
spec
es, in part or in w
– Install cooling system charge unit - VAS 6096- on adapter -
t to the co
V.A.G 1274/8- .
– Feed vent hose -2- into a small container -3-.
rrectness of i
l purpos
Note
nform
ercia
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
m
at
om
ion
c
in t
or
– Close valves -A- and -B- (turn lever transverse to direction of
his
e
satelettronica
t
flow to do this).
a
do
priv
cum
or
– Connect hose -4- to compressed air.

f
en
ng
t.
yi Co
• Pressure: 6 to 10 bar. Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
AG. Volkswagen AG d
5-cylinder diesel
ksw
engine
agen - Edition 03.2018 oes
n
ol ot g
yV ua
db ra
– Open valve -B-;oris turn lever in direction of flow to do this.ntee
e
th or
au
• In cooling
ss system, vacuum is generated by suction jet pump;
ac
needle of gauge must move into green area.
ce
e
nl
pt
du
an
– In addition, open valve -A- briefly by turning lever in direction
itte
y li
erm
of flow until expansion tank hose of cooling system charge unit
ab
ility
- VAS 6096- fills with coolant.
ot p
wit
, is n
– Close valve -A- again.
h re
hole
spec
– Leave valve -B- open for a further 2 minutes.
es, in part or in w
t to the co
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in green
range.
rrectness of i
– Close valve -B-.
l purpos
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
nform
ercia
sequent filling.
m
at
• If the needle does not reach the green zone, repeat the proc‐
om
ion
ess.
c
in t
or
his
te
• If vacuum drops, cooling system must be checked for leaks.

a
satelettronica
do
priv
cum
or
– Pull off compressed air hose.

f
en
ng
t.
yi Co
– Open valve -A-. ht. Cop py
rig
rig ht
• The vacuum in the cooling system causes coolant to be ex‐ py by
co Vo
tracted from coolant expansion tank of cooling system charge
by lksw
cted agen
Prote
unit - VAS 6096- and the cooling system to be filled.
AG.
– Remove cooling system charge unit - VAS 6096- from coolant

expansion tank.
– Fill coolant up to max. mark.
– Close coolant expansion tank.
– If fitted, switch off air conditioning system.
– Start engine and maintain engine speed at approx. 2000 rpm
for about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
• Allow engine to cool down to ambient temperature.
WARNING

– Check coolant level and top up as needed.

• The coolant level must be at the max. marking when the en‐
gine is warm.
• When the engine is cold, the coolant level must be between
min. and max. marking.

1.2.2 Charging the cooling system in the case

of emergency
AG. Volkswagen AG d
agen oes
ksw
Note byV
ol not
gu
ara
ed
ris nte
o e
♦ The following
aut steps only apply in the case of a breakdown.or a
h
ss c
♦ Here, the cooling system is charged without using the cooling
ce
e
nl
pt
system charge unit - VAS 6096- .
du
an
itte
y li
erm
♦ Charging in the case of an emergency is only permissible to
ab
ility
keep the vehicle mobile and does not replace the proper
ot p
wit
charging procedure according to the repair manual.
, is n
h re
hole
♦ After an emergency charging, the vehicle should be brought
spec
to a workshop as soon as possible where the cooling system
es, in part or in w
t to the co
should be filled properly in accordance with the repair manual.
rrectness of i
l purpos
WARNING
satelettronica
nf
ercia
o
rm
m
atio
om
n in
or c
– Open filler cap on coolant expansion tank. thi

te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, always use only distilled
water when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may AG. Volkswagen AG d
reduce corrosion protection substantially. The resulting dam‐ lksw
agen oes
not
age could lead to loss of coolant and subsequent severe by Vo gu
ara
damage to the motor.
d
rise nte
o e h
ut or
♦ Mixed in the proper proportions, coolant inhibits frost and
ss cor‐
a ac
rosion damage as well as scaling. Such additives also raise
ce
e
nl
pt
the boiling point of the coolant. For this reason, the cooling
du
an
itte
system must be filled all-year-round with coolant additives.
y li
satelettronica
erm
ab
ility
♦ Because of its high boiling point, the coolant improves engine
ot p
reliability under heavy loads, particularly in countries with trop‐
wit
, is n
h re
ical climates.
hole
spec
♦ The refractometer - T10007A- must be used to determine the
es, in part or in w
t to the co
current anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
rrectness of i
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
l purpos
ever, be increased only to a maximum of -48°C. Otherwise,

the cooling effect will be impaired.
nform
ercia
♦ The coolant concentration must not be reduced by adding wa‐

m
at
ter even in warmer seasons and in warmer countries. Frost
om
io
protection must be guaranteed down to at least -25°C.
n
c
in t
or
his
e
♦ Read off anti-freeze figures for respective replenished coolant

at
do
riv
additives.
p
cum
for
en
g
♦ The temperature read off the refractometer - T10007A- corre‐

n
t.
yi Co
sponds the ice flocculation point. Flakes of ice may start Cop py
t. rig
forming in the coolant below this temperature. opyri
gh by
Vo
ht
c
♦ Never reuse old coolant.
by lksw
cted agen
Prote AG.
♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.
Coolant mixture ratio

• Coolant additive (40%) and distilled water (60%) for frost pro‐
tection to -25°C
• Coolant additive (50%) and distilled water (50%) for frost pro‐
tection to -36°C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
– Fill a suitable container with pre-mixed coolant observing the
correct mixing ratio.
– Fill the cooling system via the coolant expansion tank up to
max. marking.
– Close coolant expansion tank.
– If fitted, switch off air conditioning system.

– Start engine and maintain engine speed at approx. 2000 rpm

for about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
WARNINGwage es n
olks ot g
byV ua
d ran
ir se
Hot steam tho may escape when expansion tank is opened. tee There‐
or
fore, cover
au sealing cap with a cloth and open it carefully. ac
ss
ce
le
un
pt
an
d
itte
– Check coolant level and top up as needed.
y li
erm
ab
ility
• The coolant level must be at the max. marking when the en‐
ot p
gine is warm.
wit
is n
h re
ole,
• When the engine is cold, the coolant level must be between
spec
min. and max. marking.
t to the co
1.3 Checking cooling system for leaks
rrectne
equipment required
satelettronica
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Cooling system tester - V.A.G 1274 B-

♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-
Prerequisites for check

• Engine at operating temperature.
• Perform cooling system leakage test using cooling system
tester - V.A.G 1274- and adapter for cooling system tester -
V.A.G 1274/8- and adapter for cooling system tester - V.A.G
1274/9- .
Test sequence
WARNING
Hot steam may escape when expansion tank is opened. Wear

eye protection and protective clothing to avoid eye injuries and
scalding. Cover cap with a cloth and carefully open.

– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
satelettronica
. Volkswagen AG
system tester - V.A.G 1274/8- . swa
gen AG does
k not
Vol gu
– Connect connector - V.A.G 1274 B/1- to edcooling system tester
by ara
nte
- V.A.G 1274 B- using supplied hose.oris eo
th
au ra
c
– Using hand pump of tester, buildssup a pressure of approx.
ce
le
1.0 bar.
un
pt
an
d
itte
y li
erm
ab
DANGER!
ility
ot p
wit
is n
Risk of scalding! Before the cooling system tester - V.A.G 1274
h re
ole,
B- is disconnected from the connecting hose or the connector
spec
- V.A.G 1274 B/1- , reduction of the pressure is essential. To
t to the co
do this, press pressure relief valve on cooling system tester -
V.A.G 1274 B- until pressure gauge displays value of »0«.
rrectne
If the pressure drops:

ss
– Find leaks and rectify.

o
cial p
f in
Checking pressure relief valve in filler cap:

form
mer
atio
– Screw cap into adapter for cooling system tester - V.A.G

om
1274/9- .
n
c
i
or
n thi
e
– Slide connector - V.A.G 1274 B/1- into adapter for cooling

t
sd
va
system tester - V.A.G 1274/9- .

i
o
pr
cum
r
fo
en
ng
– Connect connector - V.A.G 1274 B/1- to cooling system tester

t.
yi Co
- V.A.G 1274 B- using supplied hose. Cop py
ht. rig
rig ht
– Operate hand pump of cooling system tester. py by
co Vo
by lksw
cted agen
• The pressure relief valve must open at a pressure of 1.4 … Prote AG.
1.6 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.

2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 87
⇒ “2.2 Removing and installing coolant temperature sender G62
”, page 89
⇒ “2.3 Removing and installing thermostat housing”, page 90
⇒ “2.4 Removing and installing coolant pump”, page 90
⇒ “2.5 Removing and installing coolant union”, page 93
⇒ “2.6 Renewing pipe connection for coolant”, page 94
2.1 Assembly overview - coolant pump, thermostat
1 - Exhaust gas recirculation

cooler
❑ Only vehicles with an
satelettronica
automatic gearbox.
coolant hoses
⇒ page 77
⇒ page 148
2 - Bolt
AG. Volkswagen AG d
❑ 10 Nm lksw
agen oes
not
Vo gu
y
3 - Upper coolant risepipe
d b ara
nte
o eo
❑ Connection
auth
diagram for ra
coolant
s hoses
s c
ce
le
⇒ page 77
un
pt
an
d
itte
4 - Seal
y li
rm
ab
pe

ility
ot
wit
, is n
5 - O-ring
h re
hole

spec
es, in part or in w
6 - Coolant temperature send‐

t to the co
er - G62-
rrectness of i
⇒ page 89
l purpos
7 - Bracket
8 - Bolt
nform
ercia
❑ 10 Nm
m
a
com
9 - O-ring
ion in
r

te o
thi
s
iva
do
10 - Union
r
rp
cum
fo

en
ng
t.
yi
coolant hoses
Co
op py
⇒ page 77 t. C rig
gh ht
yri by
❑ Removing and installing ⇒ page 93 cop Vo
by lksw
cted agen
Prote
11 - Bolt
AG.
❑ M6: 10 Nm
❑ M8: 20 Nm
2. Coolant pump, regulation of cooling system 87

12 - Seal
13 - Lower coolant pipe
❑ Connection diagram for coolant hoses ⇒ page 77
14 - Seal
15 - Thermostat
❑ Checking: heat thermostat in water.
❑ Begins to open at approx. 80°C
❑ Ends at approx. 105°C.
❑ Opening lift min. 7 mm
16 - Thermostat housing
❑ Connection diagram for coolant hoses ⇒ page 77
satelettronica
❑ To remove, first remove connection from turbocharger ⇒ Item 9 (page 101) .
❑ Removing ⇒ page 90
17 - Connection hose
18 - Seal
19 - Coolant drain plug
❑ Remove to remove coolant pump. AG. Volkswagen AG d
agen oes
❑ 20 Nm Volksw not
g by ua
ed ra
20 - Overflow hole horis nte
eo
ut
❑ Up to engine ss a code: ► AXD 010207 plug with overflow hole ra
c
❑ From engine code: AXD 010207 ► banjo bolt with water drain hose
ce
e
nl
pt
du
an
❑ Up to engine code: ► AXE 007588 plug with overflow hole

itte
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erm
ab
❑ From engine code: AXE 007588 ► banjo bolt with water drain hose
ility
ot p
❑ If coolant flows out at the plug with overflow hole or at banjo bolt with drain hose, the coolant pump must
wit
, is n
be renewed.
h re
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
21 - Coolant pump
rrectness of i
22 - Bolt
❑ 25 Nm
l purpos
23 - Cover
nf
ercia

orm
m

atio
om
n in
❑ Lightly coat seal with oil when installing.

or c
thi
te
24 - Nut
sd
iva
o
r
rp
cu
❑ 84 Nm
o
m
f
en
ng
t.
yi
25 - Gear wheel
Co
Cop py
t. rig
❑ For coolant pump opyri
gh by
Vo
ht
❑ Check for damage by c lksw

cted agen
Prote AG.
26 - Bolt

❑ 20 Nm +90°
2.2 Removing and installing coolant temper‐

ature sender - G62-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
satelettronica
Removing
rrectness of i
sition .
l purpos
– Thoroughly clean all joints and surrounding areas before dis‐

mantling.
nform
ercia
– Remove bolt -1-.

m
at
om
ion
– Remove tab from coolant temperature sender - G62-
c
in t
or
his
te
– Remove coolant temperature sender - G62- from cylinder.

a
do
priv
cum
or
– Remove old O-ring for coolant temperature sender - G62- from

f
en
ng
mounting hole.
t.
yi Co
Cop py
t. rig
Installing opyri
gh by
Vo
ht
c
by lksw
cted agen
Prote AG.
Note
O-ring for coolant temperature sender - G62- always has to be

renewed.
– Fit new O-Ring in mounting hole.

– Fit coolant temperature sender - G62- .
– Hold bolt with tab in place, screw bolt in finger-tight and then
tighten to specified torque.
– Secure lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front; Lock carrier - service position .
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 87

2.3 Removing and installing thermostat

housing
Removing thermostat housing
AG. Volkswagen AG d
agen oes
– Remove turbocharger connection
Vol ⇒ page 100 .
ksw not
gu
y
db ara
– Loosen hose clip -arrow-. rise nte
tho eo
au ra
– Unscrew bolts -1-, and
s remove thermostat
s housing. c
ce
e
nl
Installing
pt
du
an
itte
y li
erm
ab
ility
ot p
Specified torques
wit
, is n
h re
hole
spec
page 87
es, in part or in w
t to the co
2.4 Removing and installing coolant pump
rrectness of i
satelettronica
l purpos
equipment required
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Refractometer - T10007 A-

♦ Spring-type clip pliers - V.A.G 1306- discontinued, use hose

♦ Assembly tool for spring-type clip pliers - VAS 5024- discon‐
tinued, use hose clip pliers - VAS 6340-
♦ Puller - T10221-
♦ Puller - T10222-
Removing
Vehicles with four-wheel drive and particulate filter
– Remove particulate filter ⇒ page 137 .
Vehicles with front-wheel drive and particulate filter
– Remove connecting clamp between turbocharger and exhaust
pipe.
– Unscrew bolts -arrows-.
– Release exhaust system bracket on subframe.
satelettronica
– Raise diesel particulate filter until coolant drain plug and cool‐
ant overflow plug are accessible. Support diesel particulate
filter in this position using piece of squared timber.
– Unscrew coolant drain plug and coolant overflow plug for cool‐
ant pump ⇒ Item 19 (page 88) and ⇒ Item 20 (page 88) .
– Release coolant expansion tank and place to one side (leaving
hoses connected).
– Remove coolant pump cover ⇒ Item 23 (page 88) .
Vehicles with manual gearbox
AG. Volkswagen AG d
agen oes
lksw not
– Remove gear selector cable -A- from gearbox selector lever d by
Vo gu
ara
and gate selector cable -B- from relay lever. To do this, orispress
e nte
securing clips -arrow 1- and -arrow 2-. aut
h eo
ra
ss c
– Remove cable support bracket -C- from gearbox by moving
ce
le
un
catch in -direction of arrow 3- (pulling back). pt

an
d
itte
y li
– Place gear selector cables to one side .
rm
ab
pe
ility
ot
– Select 5th or 6th gear.

wit
, is n
h re
Vehicles with automatic gearbox

hole
spec
es, in part or in w
t to the co
– Remove sealing cover -arrow- from face of sealing flange us‐

rrectness of i
ing extractor hook - 10 - 221- .

l purpos
Note
nform
mercia
Renew sealing cover after removing.

a
com
tion in
r
te o
thi

s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted
91
agen
Prote AG.
2. Coolant pump, regulation of cooling system
AG. Volkswagen AG d
agen oes
ksw
Transporter 2004 ➤ by
Vol not
gu
d ara
5-cylinder diesel engine
oris - Edition 03.2018
e nte
h eo
aut ra
ss c
ce
le
un
pt
Note
an
d
itte
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erm
ab
♦ It is only possible to bolt special wrench - T10225- onto crank‐
ility
ot p
shaft in one position.
wit
is n
h re
♦ To remove the coolant pump, the engine must not be at TDC.
ole,
spec
– Counterhold at special wrench - T10225- using suitable tool.
t to the co
rrectness
– Loosen coolant pump securing nut -1-.
o
cial p
f inform
mer
Note
atio
om
n
c
i
or
n
For engines manufactured in the first batch, puller - T10221- can‐
thi
te
sd
not be fitted due to lack of clearance behind coolant pump gear.
iva
o
r
In this case release the gear wheel by tapping lightly on the sides
p
cum
r
fo
of the gear wheel with a hammer and copper drift.
satelettronica
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Position puller - T10221- as shown and turn hex head clock‐

wise until gear can be removed from pump.
– Unscrew coolant pump securing bolts -arrows-.

– Fit puller - T10222- and turn its bolt clockwise until puller first
contacts cylinder block as shown and subsequently pulls cool‐
ant pump out.
Installing
– Wet new O-rings with coolant; do not use any other lubricants.
– Fit coolant pump.
– Use new securing bolts for coolant pump.
– Fit gear wheel and tighten securing nut.
– Fit and tighten drain plugs.
– Lightly lubricate sealing lip of coolant pump cover.
– Install coolant pump cover .
– Install particulate filter ⇒ page 137 .
Specified torques
satelettronica
page 87
2.5 Removing and installing coolant union

♦ Torque wrench - V.A.G 1331- lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
♦ Hose clamp pliers - VAS 6340-

rrectness of i
♦ Universal cloth - VAS 6385-

l purpos
nf
ercia

orm
m
atio
m
WARNING
o
n in
or c
thi
te
sd
a
Danger of scalding injuries.

iv
o
r
rp
cu
o
The cooling system is pressurised. When the engine is warm,

f
en
ng
t.
the coolant temperature may be above 100°C.
yi Co
Cop py
t. rig
Before opening, cover cap with cloth and open carefully.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
sition .

– Pull coolant hose off connection.

– Unscrew securing bolts -4- for pipe union -3- and remove pipe
union -3-.
– Remove gasket -2- and O-ring -1-.
– Clean seat surfaces for O-ring and flange on union.
– Clean sealing surfaces on cylinder head with commercially
available brake cleaner and lint-free cleaning cloth (e.g. uni‐
versal cloth - VAS 6385- ).
Installing
Note
♦ Moisten new O-ring with coolant. Do not use any other lubri‐
cant.
♦ Press pipe union with O-ring in, taking care not to jam.
satelettronica
– Install union.
– Screw in securing bolts finger-tight and then tighten to speci‐ agen
AG. Volkswagen AG d
oes
fied torque. yV
olksw not
gu
d b ara
e
– Secure coolant hose to union. horis nte
eo
aut ra
– Add coolant ⇒ page 78 . ss c
ce
le
un
pt
– Secure lock carrier ⇒ General body repairs, exterior; Rep. gr.
an
d
itte
50 ; Body - front; Lock carrier - service position .
y li
erm
ab
ility
Specified torques
ot p
wit
is n
h re
ole,
page 87
spec
t to the co
2.6 Renewing pipe connection for coolant
rrectne
♦ Press tool - T10418-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove charge air pipes between charge air cooler and tur‐
bocharger.
– Remove upper coolant pipe.

– Clean union hole in cylinder head.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
Clean area -arrow- around pipe union and apply sealant - D 000
wit
is n
h re
600 A2- there.
ole,
spec
– Drive pipe union into union hole in cylinder head as far as stop
t to the co
-arrows- using thrust piece - T10418- -1-.
– Install upper coolant pipe.
rrectne
– Install charge air pipes between charge air cooler and turbo‐
charger.
satelettronica
ss
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

wage
n A03.2018
G. Volkswagen AG d
oe
ks s no
Vol t gu
d by ara
e nte
ris
3 Radiator, radiator fan au
tho eo
ra
ss c
⇒ “3.1 Assembly overview - radiator/radiator fan”, page 96
ce
le
un
pt
an
d
⇒ “3.2 Assembly overview – fan support”, page 97
itte
y li
rm
ab
pe
⇒ “3.3 Removing and installing radiator”, page 98
ility
ot
wit
, is n
3.1 Assembly overview - radiator/radiator fan
h re
hole
spec
es, in part or in w
t to the co
1 - Radiator/cooler
coolant hoses
rrectness of i
⇒ page 77
l purpos
2 - Rubber mounting
3 - Bolt
nform
ercia
❑ 10 Nm
m
a
com
ti
4 - O-ring
on in
r
te o
thi
satelettronica
s
iva
do
5 - Upper coolant hose
r
rp
cum
fo
en
ng
t.
yi Co
coolant hoses Cop py
⇒ page 77
t. rig
gh ht
pyri by
Vo
o
6 - Radiator fan support
by c lksw
cted agen
Prote AG.
⇒ page 97
7 - Lower coolant hose
coolant hoses
⇒ page 77
8 - Radiator fan
❑ Vehicles with optional
equipment only.
⇒ page 97
9 - Connector
10 - Radiator fan
⇒ page 97
11 - Coolant expansion tank
❑ Test cooling system for leaks using cooling system tester - V.A.G 1274 B- and adapter for cooling system
tester - V.A.G 1274/8- ⇒ page 85 .
12 - Bolt
❑ 3 Nm
13 - Seal
14 - Cap
❑ Check using cooling system tester - V.A.G 1274 B- and adapter for cooling system tester - V.A.G 1274/9-
⇒ page 85 .
15 - Bracket
❑ For fan connector.

16 - Retaining clip
17 - Coolant temperature sender - radiator outlet - G83-
18 - Bracket
19 - Rubber mounting
3.2 Assembly overview – fan support
Note
AG. Volkswagen A
To remove fan support owith ksw fans, the lock carrier must
agen G do
es n be moved
V l
to service position ⇒d byGeneral
ot g
body repairs, exterior; Rep. ua gr. 50 ;
ran
Lock carrier - service
orise
position . tee
th or
s au ac
s
ce
le
un
pt
1 - Radiator fan - V7-
an
d
itte
y li
❑ Variation depending on
erm
ab
vehicle equipment.
ility
ot p
satelettronica
wit
is n
2 - Nut
h re
ole,
❑ 6 Nm
spec
3 - Clip for securing line
t to the co
❑ Ensure firm seating
4 - Radiator fan support rrectne
5 - Radiator fan 2 - V177-
ss
❑ Variation depending on
o
cial p
vehicle equipment.
inform
mer
6 - Bolt
atio
m
❑ 6 Nm
o
n
c
i
or
n thi
7 - Bolt
te
sd
iva
❑ 6 Nm
pr
cum
r
fo
en
ng
8 - Bolt
t.
yi Co
op py
❑ 5 Nm t. C rig
gh ht
pyri by
9 - Bracket
co Vo
by lksw
cted agen
Prote
❑ For lines
AG.
3. Radiator, radiator fan 97

3.3 Removing and installing radiator

equipment required
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
♦ Refractometer - T10007 A- rrectnes
♦ Spring-type clip pliers - V.A.G 1306- discontinued, use hose
s o

cial p
f inform
mer
♦ Torque wrench - V.A.G 1331- (5 … 50 Nm)

atio
m
♦ Assembly tool for spring-type clip pliers - VAS 5024- discon‐

o
n
c
tinued, use hose clip pliers - VAS 6340-

or
n thi
te
sd
va
Removing
i
o
pr
cum
r
fo

en
ng
t.
yi Co
op py
– Pull all coolant hoses off radiator. . C rig
ht ht
rig by
py
– Remove front bumper ⇒ General body repairs, exterior; Rep.
co Vo
by lksw
cted
gr. 63 ; Assembly overview - front bumper .
agen
Prote AG.

sition .
– Remove charge air cooler ⇒ page 109 .

AG. Volkswagen AG d
– Unscrew securing bolt -2- of engine oil cooler for power-as‐ wage
n oes
olks not
sisted steering. db
y V gu
ara
e nte
ris
– Unclip engine oil cooler and lay to one side. utho eo
ra
a c
ss
– Remove condenser securing bolts -3-, -6- and -8-.
ce
le
un
pt
– Lever condenser out of retainers -4- and -5- and place to side
an
d
itte
y li
(refrigerant lines remain connected).
erm
ab
ility
ot p
– Remove radiator securing bolt -1- and push rubber mounting
wit
is n
-in direction of arrow-.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
– Separate connectors -arrows-.
om
satelettronica
n
c
i
or
n
– Remove radiator forwards.
thi
te
sd
va
Installing
i
o
pr
cum
r
fo
en
ng
Install in reverse order of removal, observing the following: yi

t.
Co
op py
t. C rig
gh ht
pyri by
Vo
– Electrical connections and routing ⇒ Current flow diagrams,
co lksw
by
cted agen
Electrical fault finding and Fitting locations. Prote AG.
– Bolt lock carrier in position: ⇒ General body repairs, exterior;

Rep. gr. 50 ; Body - front; Lock carrier - service position .
– Installing front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Assembly overview - front bumper .
– Check headlight adjustment and correct if necessary ⇒ Main‐
tenance ; Booklet 19.1
3. Radiator, radiator fan 99

21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 100
⇒ “1.2 Assembly overview - turbocharger”, page 102
⇒ “1.3 Removing and installing turbocharger”, page 103
⇒ “1.4 Removing and installing turbocharger”, page 105
1.1 Assembly overview - turbocharger
Note
♦ All hose connections are secured with hose clips or retaining

clips.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
satelettronica
♦ After installing turbocharger run engine for approx. 1 minute
at idling speed, do not rev engine. This ensures that the tur‐
bocharger/compressor is adequately lubricated.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
100 Rep. gr.21 - Turbocharging/supercharging

1 - Connecting pipe
lation
2 - Bolt
❑ 10 Nm
3 - Connecting clamp
❑ 8 Nm
4 - Bracket/lifting eye
5 - Seal
olkswagen AG
AG. Vpo‐
❑ Observe installation
agen does
ksw
sitionby Vol not
gu
a
d ran
se
6 - Boltthori tee
or
au ac
❑ss 25 Nm
ce
e
nl
7 - Exhaust manifold
pt
du
an
itte
y li
8 - Connection hose
erm
ab
ility
satelettronica
ot p
❑ From air filter

wit
, is n
h re
9 - Connection
hole
spec
10 - Bolt
es, in part or in w
t to the co
❑ 8 Nm
11 - O-ring
rrectness of i

l purpos
12 - Exhaust turbocharger
❑ To remove, first remove
nform
ercia
rear torque reaction

support.
m
at
om
io
13 - Cylinder block
n
c
in t
or
his
e
14 - Bolt
at
do
riv
❑ 40 Nm
p
cum
for
en
ng
15 - Seal
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
16 - Vacuum line by c lksw
cted agen
Prote AG.
17 - Retaining bracket
18 - Nut
❑ 40 Nm
19 - Bolt
❑ 40 Nm
❑ For front exhaust pipe
❑ 8 Nm
21 - Front exhaust pipe
22 - Washer
23 - Nut
❑ 25 Nm
1. Exhaust turbocharger 101

24 - Exhaust gas recirculation cooler

❑ Only vehicles with an automatic gearbox.
1.2 Assembly overview - turbocharger
Note
♦ All hose connections are secured with hose clips or retaining clips.
♦ Charge air system must be free of leaks.
♦ After installing turbocharger run engine for approx. 1 minute at idling speed, do not rev engine. This ensures
that the turbocharger/compressor is adequately lubricated.
1 - Bracket
cooler
satelettronica
3 - Seal
4 - Exhaust gas temperature
sender 1 - G235-
❑ Lubricate thread of
sender using high-tem‐ n AG. Volkswagen AG do
perature paste - G 052 olkswage es n
ot g
112 A3- d byV ua
ran
ir se
❑ Removing and installing tho tee
or
⇒ page 144 ss
au ac
❑ 45 Nm
ce
e
nl
pt
du
an
itte
5 - Bolts
y li
erm
ab
ility
ot p
wit
❑ Do not grease
, is n
h re
hole
Tightening sequence:
spec
♦ Tighten bolts by hand.
es, in part or in w
t to the co
♦ Tighten bolts one by one to
30 Nm in 90° steps
rrectness of i
♦ Turn bolts 180° further
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6 - Washer
7 - Seal
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❑ To remove, remove tur‐

um
for
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bocharger ⇒ page 105 ,

n
t.
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⇒ Item 17 (page 103) . Cop py
and loosen exhaust gas recirculation cooler. Do not open cooling circuit.
t rig
gh ht
pyri by
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co
9 - Nut
by lksw
cted agen
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❑ 25 Nm

10 - Flange upper part

11 - Seal
❑ From air filter
13 - Clip
14 - Vacuum line
15 - Hexagon nut
❑ 40 Nm +90°
16 - Bolt
❑ Renew after removal AG. Volkswagen AG d
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❑ 40 Nm +90° olksw not
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17 - Exhaust turbocharger ris
satelettronica
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❑ Removing and installing ⇒ page
ss a
105 c
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nl
18 - Seal
pt
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19 - Clip
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❑ 7 Nm
spec
es, in part or in w
t to the co
20 - Particulate filter
21 - Seal
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22 - Flange lower part

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23 - Seal
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24 - Bracket upper part

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25 - Vacuum actuator
Co
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❑ For bypass flap. rig ht
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❑ Renew only together with exhaust gas recirculation cooler
by c lksw
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Prote AG.
26 - Bolt
❑ 15 Nm
1.3 Removing and installing turbocharger


AG. Volkswagen AG d
agen oes
olksw not
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Removing
un
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ab
Caution
pe
ility
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, is n
If a mechanical fault is found on the turbocharger, e.g. a de‐
h re
hole
stroyed compressor impeller, just renewing the turbocharger is
spec
not enough. To prevent this from causing further damage, per‐
es, in part or in w
form the following repairs:
t to the co
satelettronica
♦ Check air filter housing, air filter element and intake hoses
for soiling.
rrectness of i
♦ Check complete charged air routing and charge air cooler
l purpos
for foreign objects.

If foreign objects are found in the charge air system, the charg‐
nform
ercia
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
m
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com
tion in
r
te o
thi
– Remove front exhaust pipe with catalytic converter

s
iva
do
⇒ page 131 .
r
rp
cum
fo
en
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– Remove rear torque reaction support.

n
t.
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Cop py
– Detach all connection and vacuum hoses from turbocharger.
ht. rig
rig ht
py by
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– Unscrew bolt -1-.
by lksw
cted agen
Prote AG.
– Loosen clamp -2- and detach from connecting pipe.

– Unscrew bolts -1-. lkswage es n
o ot g
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spec
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t to the co
– Unscrew bolts -2- and remove angle bracket -1-.
rrectness of i
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nf
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orm
m
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satelettronica
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Cop py
t. rig
– Unscrew bolts -1-. gh ht
pyri by
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– Remove turbocharger. Prote
cted AG.
agen
Installing
Specified torques
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 100
1.4 Removing and installing turbocharger

♦ Hexagon bit, long reach - VAS 3410-

AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1331- agen oes
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pt
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Removing
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– Remove particulate filter ⇒ page 137 .
l purpos
– Detach all connection and vacuum hoses from turbocharger.
nform
ercia
– Remove rear torque reaction support.

m
– Unscrew bolts -1, 2, 3- from turbocharger.
at
om
io
satelettronica
n
c
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or
his
ate
do
priv
cum
for
en
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t.
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Cop py
ht. rig
rig ht
– Unscrew bolt -1-. py by
co Vo
by lksw
cted agen
– Unscrew nuts -2-. Prote AG.
– Remove turbocharger.

Installing
– Clean exhaust manifold connections using sandpaper.
Note
The abrasive paper grade must not be less than 100.
– Fix a new sealing set to exhaust manifold, e.g. using a cable

tie.
– Locate turbocharger on cylinder block studs.
Caution
If the assembly sequence is not followed, the seal may be

damaged and exhaust emissions may escape.
satelettronica
– Tighten bolt -1-.
– Tighten nuts -2-.
– Remove cable tie from seal set.
– Position bolts on turbocharger.
lkswage es n
o ot g
byV ua
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ir se tee
tho
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a ac
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nl
pt
du
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ab
ility
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, is n
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hole
– Insert gauge - T10348- -1- in -direction of arrow A- and turn in

spec
-direction of arrow B-.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Gauge - T10348- -1- must be located between upper and low‐

er parts of flange.
– Tighten bolts -1, 2, 3- hand-tight.

– Slacken bolts by 180°.
– Remove gauge - T10348- from turbocharger.
– Tighten bolts one by one to 30 Nm in 90° steps.
– Then turn all bolts 180° further.
– Install rear torque reaction support.
satelettronica
– Install particulate filter ⇒ page 137 .
Specified torques lkswage es n
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byV ua
ed ran
♦ ⇒ “1.2 Assembly overview or - turbocharger”, page 102
is tee
th or
au ac
♦ ⇒ “2.1 Assembly overview
ss - particulate filter”, page 136
ce
le
un
♦ Subframe; Assembly overview - subframe ⇒ Running gear,

pt
an
d
itte
axles, steering; Rep. gr. 40 ; Subframe; Assembly overview -

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erm
ab
subframe
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2 Charge
agen
air
AG. Vosystem
lkswagen AG
doe
w s no
olks
⇒ “2.1 Assembly
ed
by
V
overview - charge air system”,
t gu
page
ara 109
ris nte
⇒ “2.2auChecking
tho charge air system for leaks”, page 110
eo
ra
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⇒ “2.3 Installing hose connections with plug-in connectors”, page
ce
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nl
111
pt
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2.1 Assembly overview - charge air system
erm
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Note
hole
spec
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♦ All hose connections of charge air system are secured by
spring-type clips or by plug-in connectors. The following points
must be observed for plug-in connectors:
rrectness of i
♦ Release connection by pulling the locking clip -arrow-.
l purpos
♦ Pull off hose or pipe without the use of tools.

♦ When installing, ensure the locking lugs -A- engage correctly.
nform
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satelettronica
m
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c
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ate
1 - Bolt
do
priv
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❑ 3 Nm
for
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2 - O-ring t. Cop py
rig
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❑ If renewed, observe fit‐
lksw
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Prote
ting instructions
AG.
⇒ page 111
3 - Charge air pipe/connecting
hose
4 - Bolt
❑ 8 Nm
5 - Charge air cooler
❑ To remove bumper cov‐
er ⇒ General body re‐
pairs, exterior; Rep. gr.
63 ; Front bumper; Re‐
moving and installing
bumper cover
6 - From turbocharger
7 - To intake connecting pipe.
8 - Charge pressure sender -
G31- with intake air tempera‐
ture sender - G42-
2. Charge air system 109

2.2 Checking charge air system for leaks

♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/10-
♦ Adapter - V.A.G 1687/4-
– Remove intake hose -1- from air filter.
– Insert adapter - V.A.G 1687/10- into intake hose -1- and se‐
cure with a clip.
– Detach hose from crankcase breather system valve and seal.
Prepare charge air system tester - V.A.G 1687- as follows:
AG. Volkswagen AG d
agen oes
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pe
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spec
es, in part or in w
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– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
rrectness of i
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Note
To turn the pressure regulating valve -2- the knob must be pulled
nform
ercia
upwards.
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– Connect charge air system tester - V.A.G 1687- to adapter - Cop py
t. rig
V.A.G 1687/10- as shown. opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- .
Note
If there is water in the sight glass, drain at water drain screw -6-.
– Open valve -3-.

– Adjust pressure to 0.5 bar with pressure control valve -2-.
Caution AG. Volkswagen AG d

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The pressure must not exceed ised 0.5 bar. If the pressure is too
b ara
nte
high this can cause damage
ut
hor
to the engine. eo
a ra
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nl
pt
– Open valve -4- and wait until test circuit is full. If necessary,
du
an
itte
readjust pressure to 0.5 bar.
y li
erm
ab
ility
– Check charge air system for leaks by listening, touching, with
ot p
wit
commercially available leak detector spray or using ultrasonic
satelettronica
, is n
h re
tester - V.A.G 1842- .
hole
spec
es, in part or in w
t to the co
Note
♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
rrectness of i
♦ If leaks occur, when doing any repair work observe notes for
l purpos
charge air system ⇒ page 109 .

♦ Depressurise test circuit by detaching coupling from adapter -
nf
ercia
V.A.G 1687/10- before removing adapter. orm

m
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2.3 Installing hose connections with plug-in

thi
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connectors
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Caution C py
ht. rig
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The seal for the push-on coupling can be damaged if the re‐ by c lksw
cted agen
taining clip is in the locked position during installation.
Prote AG.
This would result in leaking.

Observe installation instructions.
Removing
– Release plug-in connector by pulling out retaining clip
-arrow-.
– Separate hose/pipe without tools.
Installing
– If renewed, place seal in groove of charge air hose.
– Make sure that the sealing ring is completely resting in the
groove all around the hose.
– Coat sealing surfaces and oil seal with oil.
2. Charge air system 111

– Bring retaining clip to release position -1-.

– Push charge air hose into coupling as far as stop.
– Bring retaining clip to locking position -2- and then press
charge air hose again.
– Pull on hose to ensure that plug-in connector is properly seat‐
ed and engaged.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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aut ra
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satelettronica
ce
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nl
pt
du
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23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Bleeding fuel system”, page 113
1.1 Bleeding fuel system

To ensure that the engine will start immediately after renewing
the fuel filter, bleed the fuel system using ⇒ Vehicle diagnostic
tester. ⇒ Maintenance ; Booklet 19.1
AG. Volkswagen AG d
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mer
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1. Injection system 113

2 Injectors
AG. Volkswagen AG d
⇒ “2.1 Assembly overview - unit injector”, page 114lkswagen oes
not
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⇒ “2.2 Removing and installing unit injector”, risepage
d 115 ara
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⇒ “2.3 Removing and installing aut
wiring harness for unit injectors”, ra
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page 118 s
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pt
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⇒ “2.4 Removing and installing O-rings for unit injector”,
an
itte
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page 120
erm
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ility
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⇒ “2.5 Visual inspection of unit injector”, page 122
wit
, is n
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2.1 Assembly overview - unit injector
hole
spec
es, in part or in w
t to the co
1 - Bolt
rrectness of i
❑ 20 Nm +90°
l purpos
2 - Nut
❑ 30 Nm
satelettronica
nf
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3 - Adjuster screw
rm
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❑ Renew each time it is

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c
separated from ball pin

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4 - Rocker arm shaft

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❑ With rocker arms
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❑ Check ball pin for signs
Co
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of wear, replace if nec‐ t. C rig
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❑ Removing and installing cted agen
Prote AG.
⇒ page 115
5 - Clamping block
6 - Bolt
❑ 12 Nm + 270°
7 - Unit injector
⇒ page 115
8 - O-ring
9 - Heat shield seal
10 - Retaining ring
114 Rep. gr.23 - Mixture preparation - injection

2.2 Removing and installing unit injector

equipment required
satelettronica
AG. Volkswagen AG d
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♦ Hexagon bit, long reach - 3410-
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♦ Puller - T10055-
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Not illustrated:
tion in
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♦ Gauge - T10210-
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Removing
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Note t. C rig
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The diesel direct injection system control unit is equipped with an Prote
cted agen
event memory. Read event memory before and after making re‐
AG.
pairs or adjustments ⇒ Vehicle diagnostic tester.

⇒ page 42 .
2. Injectors 115
– Turn crankshaft with special wrench - T10225- ⇒ page 49 until

cam pair for unit injector which is to be installed or removed
points evenly upwards.
– Loosen lock nuts of adjuster screws -1- and unscrew adjuster
screws until relevant rocker arm lies against plunger spring of
unit injector.
– Loosen securing bolts -2- for rocker arm spindle from outside
to inside using XZN 10 socket - 3410- and remove rocker arm
spindle.
– Loosen securing bolt -3- for clamping block using XZN 10
socket - T10054- and remove clamping block.
– Prise off connector from unit injector using screwdriver. To
avoid canting, support opposite side of connector with light
finger pressure.
satelettronica
AG. Volkswagen AG d
agen oes
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co lksw
by
cted agen
Prote AG.

– Insert puller in place of clamping block in slot on side of unit

injector.
– Pull unit injector upwards out of cylinder head seat by means
of gentle tapping.
Installing
Note
♦ If a new unit injector is installed, the appropriate adjustment

screw in the rocker arm must also be renewed.
♦ Each time work is performed which requires
wage
n AGadjustment
. Volkswagen Aof
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oe
unit injector, the adjustment screw Vol in the rocker arm and also ot gu
ks sn
by
the unit injector ball stud must
ise
d be renewed. ara
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♦ New unit injectors are supplied
sa
u with O-rings and insulating or
ac
seals. s
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un
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– Heat insulating seal and O-rings must be renewed if old unit
y li
erm
ab
injector is reused ⇒ page 120 .
satelettronica
ility
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wit
– Check that 3 O-rings, heat shield seal and retaining ring are
is n
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seated correctly before installing unit injector.
ole,
spec
t to the co
Note
The seals must not be twisted.
rrectne
– Lubricate seals and insert unit injector into cylinder head with
ss
extreme care.
o
cial p
– Apply even pressure to push unit injector into cylinder head f inform
mer
seat as far as stop.

atio
om
– Insert clamping block in slot on side of unit injector.

c
i
or
n thi
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Note
um
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t.
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If the unit injector is not at right angles to the clamping block the C py
t. rig
securing bolt may loosen and this can damage the unit injector or
gh ht
yri by
the cylinder head.
cop Vo
by lksw
cted agen
Prote AG.
– Align unit injector as follows:

– Screw new securing bolt as far as possible into clamping block
while still being able to turn unit injector easily).
– Position gauge - T10210- between mounting seat and unit in‐

jector as shown.
– Turn unit injector manually against gauge.
– Realign unit injector if necessary and tighten securing bolt.
– Fit rocker arm shaft, and tighten new securing bolts.
– Tighten inner and then both outer bolts hand-tight. Tighten in
same sequence.
2. Injectors 117
– Fit dial gauge onto adjustment screw of unit injector as shown.

– Turn crankshaft in direction of engine rotation until roller of
rocker arm is located at tip of drive cam. Roller side
-arrow A- positioned at highest point, dial gauge -arrow B-
positioned at lowest point.
– Remove dial gauge.
– Now turn adjustment screw into rocker arm against spring
pressure of unit injector until a firm resistance is felt (unit in‐
jector positioned at limit stop). Volkswa AG. gen AG
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– Slacken adjustment
s au screw of stop by 180°. ra
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– Hold adjuster bolt in this position and tighten lock nut.

nl
pt
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– Locate unit injector connector and fit cylinder head cover.
erm
ab
ility
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Specified torques
wit
, is n
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♦ ⇒ “2.1 Assembly overview - unit injector”, page 114
hole
spec
satelettronica
es, in part or in w
t to the co
rrectness of i
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2.3 Removing and installing wiring harness

for unit injectors
nf
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♦ Puller - T10312-

Removing
sition .
– Separate electric multi-pin connector for unit injectors. To do
so, pull release pin -arrow 1- and loosen knurled nut
-arrow 2-.
satelettronica
Note
Only puller - T10312- must be used to unplug electrical connec‐

tors on piezo unit injectors. olkswage es n
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– Prise off connector from unit injector using screwdriver
ole,
-arrow-. To avoid canting, support opposite side of connector

spec
with light finger pressure.

t to the co
rrectness o
cial p
f inform
mer
atio
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Prote AG.
2. Injectors 119
– Locate special wrench - T10211- on adapter ring and loosen

by turning anticlockwise through 90° -arrow-.
– Unplug connector from cylinder head and remove entire pre‐
wiring.
Installing
– Fit prewiring harness and tighten securing bolts.
– Route central connector through opening in frame of mount‐
ing. Ensure it is seated correctly.
– Tighten adapter ring with special wrench - T10211- by turning
90° in clockwise direction.
Note
When adapter ring is installed correctly the colour marked “short‐

er” stud faces 12 o'clock)
• Long green line faces upwards.
satelettronica
– Tighten central connector on cylinder head and lock in place.
– Install engine cover panel and cylinder head cover
– Install intake manifold ⇒ page 126 .
Specified torque
. Volkswagen AG
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2.4 Removing and installing O-rings for unit ss c
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injector pt
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– Lever old O-rings very carefully out of unit injector.

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Installing
Note
♦ Always use the assembly sleeves to fit the O-rings. There is a

danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings without different coloured
markings. Note the correct allocation of O-rings to grooves:
the thickness of the rings reduces towards injector nozzle.
♦ Prevent O-rings from rolling when sliding them on. The O-rings
must not be twisted in their seats in unit injector.
– Remove heat shield seal together with retaining ring.

– Clean seating surfaces for O-rings on unit injector very care‐
fully.
– Slide assembly sleeve - T10056/1- onto unit injector as far as
stop.
– Push upper, thicker O-ring carefully onto assembly sleeve and
into seat on unit injector. n AG. Volkswagen AG do
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– Remove assembly
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– Push middle, thinner O-ring carefully onto assembly sleeve

and into seat on unit injector.
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– Remove assembly sleeve.

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– Remove assembly sleeve.
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– Slide new heat shield seal together with retaining ring into po‐
sition.
2. Injectors 121
2.5 Visual inspection of unit injector
Note
♦ Ensure that no diesel fuel contacts coolant hoses. If necessa‐

ry, clean hoses immediately.
♦ Observe relevant disposal regulations.
– Remove unit injector ⇒ page 115 .

– Carry out visual inspection for leaks in unit injector, renewing
seals and O-rings if necessary ⇒ page 120 .
– Carry out visual check of copper ring -arrow- of unit injector
Note
Leaks in lower part of unit injector can be identified by means of

»black deposits«.
satelettronica
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3 Vacuum system
⇒ “3.1 Vacuum hose schematic diagram”, page 123
⇒ “3.2 Vacuum hose schematic diagram”, page 124
3.1 Vacuum hose schematic diagram
1 - Charge pressure control

solenoid valve - N75-
2 - Variable intake manifold
flap changeover valve - N239-
valve - N18-
4 - Breather valve
5 - Brake servo line
6 - Vacuum reservoir
7 - Non-return valve
satelettronica
sition
❑ White connection to
charge pressure control
solenoid valve
⇒ Item 1 (page 123) and
to vacuum reservoir
olkswagen AG
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❑ Can only be renewed to‐

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necting pipe
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10 - To vacuum unit.
spec
es, in part or in w
❑ For charge pressure

t to the co
control.
❑ Integral part of turbo‐
rrectness of i
charger and cannot be

replaced
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3. Vacuum system 123

3.2 Vacuum hose schematic diagram

cooler changeover valve -
N345-
lation cooler
2 - Charge pressure control
solenoid valve - N75-
3 - Vacuum reservoir
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4 - Brake servo line agen oes
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❑ Observe installation
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un
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❑ Black connection to
an
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brake servo line
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⇒ Item 4 (page 124)
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6 - Air filter
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7 - Change-over flap
spec
t to the co
lation cooler
8 - Exhaust turbocharger
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4 Senders and sensors

⇒ “4.1 Removing and installing fuel temperature sender G81 ”,
page 125
4.1 Removing and installing fuel tempera‐

ture sender - G81-
♦ Hose clamps to 25 mm - 3094-
Removing
The fuel temperature sender - G81- is located in the return hose
from the tandem pump to the fuel filter.
WARNING
Observe the following points during all installation work, in epar‐

olks
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♦ Route all the various lines (e.g. for fuel, hydraulics,
ed coolant
satelettronica
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and refrigerant, brake fluid and vacuum) ut and electrical
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wiring in their original positions. ss
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hot components.
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– Clamp off return line with hose clips up to 25 mm - 3094- in
h re
front of and behind fuel temperature sender - G81- .
hole
spec
es, in part or in w
– Unplug connector -2- from fuel temperature sender - G81- .
t to the co
– Pull off clip -1- and remove fuel temperature sender - G81- .
Installing
rrectness of i
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♦ Always renew seal.
nform
mercia
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4. Senders and sensors 125

5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 126
⇒ “5.2 Assembly overview – intake manifold flap”, page 127
⇒ “5.3 Assembly overview – intake manifold flap”, page 128
5.1 Assembly overview - intake manifold
1 - Cylinder head
⇒ page 46
2 - Intake manifold support
3 - Bolt AG. Volkswagen AG d
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❑ 10 Nm Volksw not
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4 - Sleeve horis nte
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5 - Intake manifold ss c
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satelettronica
❑ To remove, move lock
un
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an
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carrier to service posi‐

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❑ Unscrew bolts
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⇒ Item 6 (page 126)
h re
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6 - Bolt
spec
es, in part or in w
❑ 20 Nm
t to the co
7 - Fuel distributor
rrectness of i
8 - Bolt
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❑ 8 Nm +90°
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9 - Union
❑ Long
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❑ For supply
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10 - Union
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❑ Short
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❑ For return
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12 - Glow plugs -Q10- / -Q14-
❑ Checking ⇒ page 156
❑ 8 mm: 12 Nm
❑ 10 mm: 15 Nm
13 - Seal

5.2 Assembly overview – intake manifold flap

The intake manifold flap is closed for approx. 3 seconds when the
engine is stopped, and then it opens again. This reduces the stop
jolt.
1 - Bolt
❑ 20 Nm
2 - Connecting pipe
lation
3 - Seal
4 - Bolt
❑ 10 Nm
5 - Vacuum actuator
6 - Bolt
satelettronica
❑ 10 Nm
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8 - Mechanical exhaust gas re‐ horis nte
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9 - Intake connecting pipe
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un
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❑ With mechanical ex‐

itte
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haust gas recirculation
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valve and intake mani‐
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fold flap
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10 - O-ring
spec
t to the co
11 - Vacuum supply
12 - Variable intake manifold
rrectne
flap changeover valve
s
13 - Intake manifold
s o
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mer
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5. Intake manifold 127

olkswagen AG
Transporter 2004 ➤ wage
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5.3 Assembly overview – intake manifold flap ss
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1 - Intake manifold
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2 - O-ring
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3 - Seal
spec
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4 - Connecting pipe
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lation
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5 - Nut
❑ 20 Nm
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6 - Bolt
m
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❑ 10 Nm
on in
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7 - Intake manifold flap motor -
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❑ The intake manifold flap
fo
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is closed for approx. 3

t.
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seconds when the en‐
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8 - Bolt
❑ 10 Nm
9 - O-ring
valve - N18- with exhaust gas
recirculation potentiometer -
G212-
❑ Assembly overview - ex‐
⇒ page 148

6 Air filter
⇒ “6.1 Assembly overview - air filter”, page 129
6.1 Assembly overview - air filter
1 - Air mass meter - G70-

2 - O-ring
3 - Air filter upper part
4 - Filter element
5 - Rubber mounting
6 - Air filter lower part
7 - Bolt
❑ 8 Nm
8 - To turbocharger
satelettronica
9 - Clip
10 - Cowling
11 - From crankcase breather
13 - Bolt
❑ 6 Nm
AG. Volkswagen AG d
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ate
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6. Air filter 129

7 Engine (motor) control unit

⇒ “7.1 Removing and installing engine control unit”, page 130
7.1 Removing and installing engine control

unit
Removing
– Before removing engine control unit, first read control unit
identification and, with it, coding of current control unit ⇒ Ve‐
hicle diagnostic tester.
– Switch off ignition.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
– Remove battery cover ⇒ Electrical system; Rep. gr. 97 ; Re‐
moving and installing fuse holders, relay carriers, electronics
boxes and control units .
– Unscrew bolts -arrows- and remove cover.
satelettronica
AG. Volkswagen AG d
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– Release and pull off engine control unit connectors -1- and ed by ara
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-2-. hor eo
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spec
t to the co
rrectne
– Remove old control unit.

Installing
ss o

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mer
– Fit new control unit.

atio
m
– Check previous coding and code new control unit ⇒ Vehicle

o
n
c
diagnostic tester.
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26 – Exhaust system
1 Exhaust pipes and silencers
⇒ “1.1 Assembly overview - silencers”, page 131
⇒ “1.2 Assembly overview - silencers”, page 133
⇒ “1.3 Separating front and rear silencers”, page 134
⇒ “1.4 Installation position of clamps”, page 135
AG. Volkswagen AG d
⇒ “1.5 Check exhaust system for leaks”, page 135 agen oes
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1.1 Assembly overview - silencers ed
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Note le
un
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♦ After working on the exhaust system, ensure that the system
pe
ility
is not under stress and that there is sufficient clearance to the
ot
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bodywork. If necessary, loosen double and single clamps and
h re
satelettronica
align silencer and exhaust pipe so that sufficient clearance is
hole
spec
maintained to the bodywork and the support rings are evenly
es, in part or in w
loaded.
t to the co
rrectness of i
WARNING
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Risk of burns.
nform
ercia
Parts of the exhaust system may be hot.

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Before removing the exhaust system, allow it to cool down.
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1. Exhaust pipes and silencers 131

sition
❑ 8 Nm
3 - Seal
4 - Mounting
5 - Front exhaust pipe with cat‐
alytic converter
6 - Bolt
❑ 25 Nm
7 - Bolt
❑ 60 Nm
8 - Rear silencer
❑ Not on all vehicles.
satelettronica
9 - Alignment dimensions in
mm
❑ -a- = approx. 5
❑ -b- = approx. 11
❑ Exhaust system must
be cold
❑ Arrow indicates front of
vehicle
mm
❑ -a- = approx. 9
❑ -b- = approx. 7 wage
es n
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❑ Exhaust system must d by V ua
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be cold orise
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❑ Arrow indicates sfront
s au
of vehicle ac
ce
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11 - Coupling point
un
pt
an
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❑ Centre and rear silencers are installed as a single component during production. In cases of repair, the
y li
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centre and rear silencer are supplied separately, with a double clamp for connecting.
ility
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❑ Separating front and rear silencers ⇒ page 134 .

wit
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12 - Centre silencer
ole,
spec
13 - Clip
t to the co

❑ 35 Nm
rrectness o
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132 Rep. gr.26 - Exhaust system

1.2 Assembly overview - silencers
Note

bodywork. If necessary, loosen double and single clamps and
align silencer and exhaust pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
AG. Volkswagen AG d
❑ Observe installation po‐ lksw
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❑ 7 Nm horis nte
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3 - Seal
satelettronica
ss c
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pt
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⇒ page 137
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5 - Front exhaust pipe
spec
es, in part or in w
6 - Bolt
t to the co
❑ 25 Nm
7 - Mounting
rrectness of i
8 - Bolt
l purpos
❑ 60 Nm
nf
ercia
9 - Rear silencer
orm
m
❑ Vehicles registered as
atio
m
commercial vehicles
o
n in
c
may only have one ex‐

or
thi
e
haust tailpipe.
t
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❑ Modification approx. as
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of model year 2008

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❑ -a- = approx. 5 Prote
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agen
❑ -b- = approx. 11
❑ Exhaust system must
be cold
❑ Arrow indicates front of
vehicle
11 - Alignment dimensions in mm
❑ -a- = approx. 9
❑ -b- = approx. 7
❑ Exhaust system must be cold
❑ Arrow indicates front of vehicle
12 - Coupling point
❑ Centre and rear silencers are installed as a single component during production. In cases of repair, the
centre and rear silencer are supplied separately, with a double clamp for connecting.

❑ Separating front and rear silencers ⇒ page 134 .
13 - Centre silencer
14 - Clip
❑ 35 Nm
1.3 Separating front and rear silencers

♦ Chain-type pipe cutter - VAS 6254-
satelettronica
WARNING
To avoid injury from metal shavings, wear
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protective clothing. db
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– Mark coupling point -a- = 144
s mm on front silencer exhaust
ce
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nl
pipe -1-.
pt
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– Cut through exhaust pipe at coupling point at right angle to

erm
ab
pipe using e.g. pneumatic sabre saw - VAS 6254- .

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– Centre repair double clamp -2- when installing.

h re
hole
spec
Torque setting M8: 35 Nm

es, in part or in w
t to the co
Torque setting M10: 52 Nm

– Align exhaust system free of stress.
rrectness of i
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at
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ion
c
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or
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1.4 Installation position of clamps

Installation position of clamp
– Install clamping sleeve so that bolt end does not protrude be‐
yond lower edge of clamping sleeve -arrow-.
Bolt connections point to the right.
1.5 Check exhaust system for leaks

– Start engine and allow to idle. n AG. Volkswagen AG do
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– Plug tailpipes (e.g. with cloths byor ua
ed ran
plugged until leak test is ocomplete.
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– Listen for noise at connection
ss
a
points (cylinder head/exhaust ac
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
ce
le
un
pt
any leaks.
satelettronica
an
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– Repair any leaks found.
ab
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2 Exhaust gas cleaning

⇒ “2.1 Assembly overview - particulate filter”, page 136
⇒ “2.2 Removing and installing particulate filter”, page 137
2.1 Assembly overview - particulate

en AG. V
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Note thoris nte
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bodywork. Loosen double clamp and clamp if necessary. Align

itte
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silencer and exhaust pipe so that sufficient clearance is main‐
ab
pe
ility
tained to the bodywork and the support rings are evenly loa‐
ot
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ded.
, is n
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hole
spec
es, in part or in w
♦ If the particulate filter or the exhaust gas pressure sensor 1 -
t to the co
G450- has been renewed, it is absolutely necessary to adapt
the exhaust gas pressure sensor 1 - G450- using ⇒ Vehicle
satelettronica
diagnostic tester.
rrectness of i
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1 - Bolt
nform
ercia
❑ 9 Nm
m
a
2 - Exhaust gas pressure sen‐
com
tion in
sor 1 - G450-
r
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❑ Adaptation ⇒ Vehicle di‐
s
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agnostic tester
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3 - Hose
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4 - Control cable
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5 - Control cable
AG.
❑ 45 Nm
6 - Clip
7 - Bolt
❑ 9 Nm
8 - Exhaust gas temperature
sender 3 - G495-
❑ Coat with high-tempera‐
ture paste - G 052 112
A3-
⇒ page 146
9 - Bolt
❑ 60 Nm
⇒ page 137
11 - To front exhaust pipe
12 - Bolt
❑ 50 Nm +90°

13 - Bracket
❑ Adhere to assembly sequence:
♦ Tighten bolts ⇒ Item 12 (page 136) and ⇒ Item 14 (page 137) hand-tight.
♦ Fit particulate filter
♦ First tighten bolt ⇒ Item 14 (page 137) , then bolt ⇒ Item 12 (page 136) to 50 Nm.
♦ Retighten bolt ⇒ Item 14 (page 137) and then bolt ⇒ Item 12 (page 136) ⇒ to 90° (1/4 turn).
14 - Bolt
❑ 50 Nm +90°
15 - Bolt
❑ 60 Nm
16 - Support
17 - Lambda probe - G39-
❑ Grease only thread with high-temperature paste - G 052 112 A3- ; high-temperature paste must not get
into slots in probe body
❑ 52 Nm
satelettronica
18 - Seal
❑ 7 Nm
21 - Exhaust gas temperature sender 2 - G448-
❑ Coat with high-temperature paste - G 052 112 A3-
❑ 45 Nm gen AG
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22 - Clip byV gu
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2.2 Removing and installing particulate filter

ility
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spec
♦ Lambda probe open ring spanner set - 3337-

t to the co
rrectness o
cial p
f inform
mer
atio
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t.
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Cop py
t. rig
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Vo
co lksw
by
137
cted agen
Prote AG.
2. Exhaust gas cleaning
Removing
WARNING
Risk of burns.
Note
When installing a new particulate filter in the vehicle, an ash mass

comparison must be carried out ⇒ Vehicle diagnostic tester.
– Unplug connectors -arrow A- and Lambda probe - G39- con‐

nector -arrow B- in engine compartment.
gen AG
. Volkswagen AG
d wa oes
olks not
– Release cable tie. byV gu
ara
ed nte
ris
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satelettronica
t
au ra
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nl
pt
du
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
– Unplug connector to exhaust pressure sensor 1 - G450- -2- t to the co

and unscrew bolt -1-.
rrectness of i
The hoses remain connected to exhaust gas pressure sensor 1 -

G450- .
l purpos
– Unclip hoses from brackets.

nform
ercia
– Loosen connecting clamp between particulate filter and tur‐

bocharger.
m
at
om
io
– Release clamp-type clip to centre silencer.

n
c
in t
or
his
ate
do
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cum
for
en
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t.
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– Remove front exhaust pipe by removing clamp -1- and un‐ Cop py
screwing bolts -arrows-.
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Unscrew hexagon bolts -arrows- from left assembly mounting.

Vehicles with front-wheel drive
– Unscrew bolts -arrows- from particulate filter.
satelettronica
– Unscrew securing bolts -arrows- for particulate filter bracket
and remove particulate filter bracket.
– Remove particulate filter.
Pay attention to lines and hoses when removing.
swage es n
– Remove front propshaft ⇒ Power transmission; byV
olk
Rep. gr. 39 ; ot g
ua
Removing and installing front propshaft
ir se .
d ran
tee
tho
or
– Position engine and gearbox jack au - VAS 6931- with universal ac
ss
support - V.A.G 1359/2- under gearbox and exert slight coun‐
ce
e
nl
ter pressure.
pt
du
an
itte
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ab
– Unscrew bolt -3- and nut -1- and remove bracket -2-.
ility
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, is n
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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or c
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Cop py
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by
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Prote AG.
2. Exhaust gas cleaning 139

– Unscrew bolts -1 and 3- and remove nut -2-.
AG. Volkswagen AG d
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nl
pt
du
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, is n
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hole
spec
– Unscrew securing bolts -1- of particulate filter.
es, in part or in w
t to the co
rrectness of i
l purpos
satelettronica
nf
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orm
m
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n in
or c
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sd
iva
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cu
– Unscrew bolts -2- from bracket and remove bracket.
o
m
f
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t.
yi
– Unscrew bolts -arrows- and remove bracket -1-.
Co
Cop py
ht. rig
– Remove engine and gearbox jack - VAS 6931- with universal
rig ht
py by
o Vo
support - V.A.G 1359/2- from beneath gearbox. by c lksw
cted agen
Prote AG.
– Remove particulate filter.
Pay attention to lines and hoses when removing.
Installing
WARNING
Ensure that the particulate filter is not installed under stress.

The particulate filter could be damaged.
Follow the installation sequence.
Vehicles with front-wheel drive

– Insert particulate filter and hand-tighten bolts -arrows- on

bracket.
Pay attention to lines and hoses.
– Locate particulate filter with new gasket on turbocharger and
hand-tighten clamp.
– Fit bolts -arrows- hand-tight. lkswage es n
o ot g
yV ua
– Tighten clamp between turbocharger and particulate
ir se
d filter.
b ran
tee
tho
u or
a ac
ss
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nl
pt
du
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itte
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erm
ab
satelettronica
ility
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, is n
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spec
es, in part or in w
t to the co
– Tighten bolts -arrow-.
rrectness of i
l purpos
nf
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orm
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or c
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Cop py
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– Tighten bolts -arrow-. yri
p by
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– Insert particulate filter and fit bracket -1-.

– Hand-tighten bracket -2- with bolt -3- on particulate filter.

– Locate particulate filter with new gasket on turbocharger and
hand-tighten clamp. At same time move address bracket -2-
to double stud and hand-tighten nut -1-.
satelettronica
– Fit bolts -2- hand-tight.
– Tighten clamp between turbocharger and particulate filter.
– Tighten bolts -2- and then bolts -1-.
AG. Volkswagen AG d
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pe
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– Tighten bolt -3-.

ot
wit
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– Install front propshaft ⇒ Power transmission; Rep. gr. 39 ;

hole
spec
Removing and installing front propshaft .

es, in part or in w
t to the co
Continuation all vehicles

– Install front exhaust pipe.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
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Cop py
t. rig
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by c lksw
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– Tighten clamp -1-.
– Tighten O-type clip.
– Screw on exhaust gas pressure sensor 1 - G450- and connect
connector.
– Clip hoses to plenum chamber bulkhead.
– Connect connectors -A- and -B- and secure wiring harnesses

with cable tie at positions marked.
Specified torques
♦ ⇒ “2.1 Assembly overview - particulate filter”, page 136
♦ ⇒ “1 Exhaust pipes and silencers”, page 131
satelettronica
AG. Volkswagen AG d
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es, in part or in w
t to the co
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nform
mercia
a
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tion in
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te o
thi
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cum
fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3 Exhaust gas temperature regulation

⇒ “3.1 Removing and installing exhaust gas temperature sender
1 G235 ”, page 144
2 G448 ”, page 145
3 G495 ”, page 146
3.1 Removing and installing exhaust gas

temperature sender 1 - G235-
n AG. Volkswagen A
olks
waequipment
ge required
G do
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by ara
♦ Tool insert, AF
ris 17 mm - T10395-
ed nte
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s au ra
c
s
ce
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an
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ab
ility
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satelettronica
wit
is n
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ole,
spec
t to the co
rrectne
Removing
ss o
cial p
WARNING
inform
mer
Risk of burns.
atio
om
n
c

i
or
n thi
te
sd
a

iv
o
pr
cum
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fo
en
ng
t.
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– Disconnect electrical connector -1- for exhaust temperature Cop py
. rig
sender 1 - G235- and free electrical wiring from cable ties
ht ht
rig by
py
-arrows-. co Vo
by lksw
cted agen
Prote AG.
Colour Designation Number

black Exhaust gas temperature sender 1 1
- G235-
brown Exhaust gas temperature sender 2 2
- G448-
orange Exhaust gas temperature sender 3 3
- G495-

– Remove exhaust temperature sender 1 - G235- -arrow- from

turbocharger.
Installing
Note
♦ Lubricate thread of the exhaust gas temperature sender with

high-temperature paste.
♦ Fit cable ties in the same place when installing.
Specified torques

satelettronica
♦ Tool insert, AF 17 mm - T10395-
AG. Volkswagen AG d
agen oes
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d by ara
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or eo
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nl
pt
du
an
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ab
Removing
ility
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WARNING
hole
spec
es, in part or in w
Risk of burns.
t to the co

rrectness of i

l purpos
– Separate electrical connector -2- for exhaust temperature

nf
ercia

or
-arrows-.
m
m
atio
om
n in
or c
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sd
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cu
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
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Prote AG.

- G235-
3. Exhaust gas temperature regulation 145

lkswage es n
o o t gu
yV
db ara
ir se nte
Colour ut
ho Designation e Number
or
s a ac
brown sExhaust gas temperature
sender 2 2
ce
e
- G448-
nl
pt
du
an
itte
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erm
ab
- G495-
ility
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wit
, is n
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hole
spec
es, in part or in w
particulate filter.
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia

m
at
om
ion
c
in t
or
his
ate
do
satelettronica
riv
Specified torques
p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
p by
co Vo
by lksw
cted agen
Prote AG.

♦ Tool insert, AF 17 mm - T10395-
Removing
WARNING
Risk of burns.

– Separate electrical connector -3- for exhaust temperature

-arrows-.
AG. Volkswagen AG d
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pt
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ab
ility
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spec
es, in part or in w
t to the co
- G235-
brown Exhaust gas temperature sender 2 2
- G448-
rrectness of i
l purpos
- G495-
satelettronica
nform
ercia
– Unclip and remove wiring from guide -1-.

m
at
om
ion
c
in t
or
particulate filter.
his
ate
do
riv
Installing
p
cum
for
en
ng
t.
Install in reverse order of removal, observing the following: Cop
yi Co
py
t. rig
gh ht
pyri by
Vo
o
Note by c lksw
cted agen
Prote AG.

Specified torques
3. Exhaust gas temperature regulation 147

4 Exhaust gas recirculation

⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 148
⇒ “4.2 Checking mechanical exhaust gas recirculation valve”,
page 151
⇒ “4.3 Checking electronic exhaust gas recirculation valve”, page
152
4.1 Assembly overview - exhaust gas recir‐

culation olkswage es n
ot g
byV ua
d
⇒ “4.1.1 Assembly overview - exhaust gas recirculation”, o
ir se
ran
tee
page 148 auth or
ac
ss
⇒ “4.1.2 Assembly overview - exhaust gas recirculation, vehicles
ce
le
un
pt
with manual gearbox”, page 150
an
d
itte
y li
⇒ “4.1.3 Assembly overview - exhaust gas recirculation, vehicles
rm
ab
pe
ility
with automatic gearbox”, page 151
ot
wit
, is n
4.1.1 Assembly overview - exhaust gas recirculation
h re
satelettronica
hole
spec
es, in part or in w
t to the co
1 - Bolt
❑ 10 Nm
rrectness of i
2 - Intake manifold flap motor -
V157-
l purpos
❑ The intake manifold flap

is closed for approx. 3
nform
ercia
seconds when the en‐

gine is stopped, and
m
a
com
t
then it opens again. This
ion in
reduces the stop jolt.
r
te o
thi
s
iva
3 - Bolt
do
r
rp
cum
❑ 10 Nm
fo
en
ng
t.
yi Co
4 - Exhaust gas recirculation . Cop py
valve - N18- with exhaust gas
t rig
gh ht
yri by
recirculation potentiometer - cop Vo
by lksw
G212- cted agen
Prote AG.
sealing surface on in‐
take manifold for soiling
and clean if necessary
❑ If the exhaust gas recir‐
culation valve - N18-
with exhaust gas recir‐
culation potentiometer -
G212- is renewed the
ignition must be switch‐
ed on and off again.
Then wait one minute
for the control unit to run
down (valve learns,
main relay must click)
❑ Start engine and run at
idling speed for one mi‐
nute.
❑ Then read engine con‐
trol unit event memory;
event memory must not contain any fault ⇒ Vehicle diagnostic tester.

5 - Intake manifold
6 - Seal
7 - Connecting pipe
8 - Bolt
❑ 22 Nm
9 - Seal
10 - Nut
❑ 25 Nm
11 - Seal
❑ Note version: Metal gasket
13 - Exhaust gas recirculation cooler changeover valve - N345-
satelettronica
15 - Bolt
AG. Volkswagen AG d
❑ 10 Nm agen oes
olksw not
y V gu
d b ara
16 - Vacuum actuator orise nte
th eo
❑ For bypass flap.
s au ra
c
s
❑ Renew only together with exhaust gas recirculation cooler
ce
e
nl
pt
du
an
17 - Exhaust gas recirculation cooler

itte
y li
erm
ab
18 - Seal
ility
ot p
wit

, is n
h re
hole
19 - Connecting pipe
spec
es, in part or in w
20 - Bolt
t to the co
❑ 22 Nm
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Cop py
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gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
4. Exhaust gas recirculation 149

4.1.2 Assembly overview - exhaust gas recirculation, vehicles with manual gear‐
box
1 - From charge air cooler

2 - Bolt
❑ 10 Nm
fold flap
4 - Mechanical exhaust gas re‐
circulation valve
ing pipe
gether with intake con‐
necting pipe
satelettronica
❑ Check mechanical op‐
eration ⇒ page 151 .
AG. Volkswagen AG d
agen
5 - O-ring olksw
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not
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❑ Renew after removal rised
nte
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6 - Intake manifold ss a ra
c
ce
le
7 - Seal
un
pt
an
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itte

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ab
pe
8 - Connecting pipe ility

ot
wit
, is n
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hole
❑ 8 Nm
spec
es, in part or in w
t to the co
11 - Bolt
rrectness of i
❑ 25 Nm
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

4.1.3 Assembly overview - exhaust gas recirculation, vehicles with automatic

gearbox
1 - Coolant hose
coolant hoses
⇒ page 77
2 - Seal
3 - Bolt
❑ 10 Nm
4 - From charge air cooler
5 - Mechanical exhaust gas re‐
circulation valve
ing pipe
satelettronica
gether with intake con‐ AG. Volkswagen AG d
necting pipe agen oes
olksw not
yV gu
❑ Check mechanical op‐ ed b ara
nte
is
eration ⇒ page 151thor . eo
au ra
c
6 - O-ring ss
ce
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nl

pt
du
an
itte
7 - Intake manifold y li
erm
ab
ility
ot p
8 - Intake connecting pipe wit

, is n
h re
hole

spec
es, in part or in w

t to the co
fold flap
9 - Radiator/cooler
rrectness of i

lation
l purpos
nf
ercia
❑ 8 Nm
orm
m
atio
om
n in
c
12 - Nut
or
thi
te

sd
iva
o
r
rp
cu
❑ 25 Nm
o
m
f
en
ng
t.
yi
13 - Bolt
Co
Cop py
t. rig
❑ 10 Nm opyri
gh by
Vo
ht
by c lksw
14 - Connecting pipe Prote
cted AG.
agen
15 - Bolt
❑ 25 Nm
4.2 Checking mechanical exhaust gas recir‐

culation valve

♦ Hand operated vacuum pump - V.A.G 1390-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
ce
le
un
pt
an
d
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erm
ab
ility
ot p
wit
is n
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ole,
spec
Note
t to the co
♦ The exhaust gas recirculation system is actuated by the en‐
gine control unit via the exhaust gas recirculation valve - N18-
rrectne
to the mechanical exhaust gas recirculation valve.
♦ The tapered plunger in the mechanical exhaust gas recircula‐
ss
satelettronica
o
tion valve varies the opening cross-section according to the
cial p
f in
opening lift.
form
mer
atio
om
n
c
i
or
n
Test sequence
thi
te
sd
iva
o
r
– Remove charge air pipe / intake connecting pipe connecting

p
cum
r
fo
hose.
en
ng
t.
yi Co
op
– Pull vacuum hose off mechanical exhaust gas recirculation C py
t. rig
valve.
gh ht
pyri by
Vo
o
by c lksw
– Connect hand vacuum pump - V.A.G 1390- to valve. cted agen
Prote AG.
– Operate hand vacuum pump - V.A.G 1390- and observe dia‐

phragm rod.
• The diaphragm rod must move in direction of arrow.
– Remove hose of hand vacuum pump - V.A.G 1390- from me‐

chanical exhaust gas recirculation valve.
• The diaphragm rod must move back to its original position
counter to the direction of the arrow
4.3 Checking electronic exhaust gas recir‐

culation valve
♦ Vehicle diagnostic tester

Note
♦ The exhaust gas recirculation system is actuated by the en‐

gine control unit via the exhaust gas recirculation valve - N18-
to the mechanical exhaust gas recirculation valve.
♦ The tapered plunger in the mechanical exhaust gas recircula‐
tion valve varies the opening cross-section according to the
opening lift.
Note
The exhaust gas recirculation valve - N18- and the exhaust gas
recirculation potentiometer - G212- are checked by means of
⇒ Vehicle diagnostic tester. swa
gen AG
. Volkswagen AG
does
olk not
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edb ara
ris nte
tho eo
au ra
satelettronica
ss c
ce
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un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

28 – Glow plug system

1 Glow plug system
⇒ “1.1 Removing and installing glow plugs Q10 / Q14 ”,
page 154
⇒ “1.2 Checking glow plugs Q10 / Q14 ”, page 156
⇒ “1.3 Removing and installing engine speed sender G28 ”, page
158
1.1 Removing and installing glow plugs -

Q10- / -Q14-
♦ U/J extension and socket, 10 mm - 3220-
satelettronica
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
♦ Torque wrench - V.A.G 1331- hor eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Conditions
• Engine is cold
nform
ercia
• Ignition switched off

m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
154 Rep. gr.28 - Glow plug system

Caution
Ceramic glow plugs are sensitive to knocks and bending. For

this reason a glow plug which has dropped from a small height
(approx. 2 cm) must not be used. Even if no damage is appa‐
rent. It is absolutely necessary to follow the installation instruc‐
tions, otherwise the heater pin of the glow plug can break and
cause engine damage.
Transport and store only in original packaging or packed sep‐
arately in bubble wrap. agen
AG. Volkswagen AG d
o w es n
olks ot g
Only remove ceramic glow plugs fromdtheir
by
V packaging imme‐ ua
ran
diately before installing them. ho
rise tee
ut or
If there is any doubt as to the sscondition
a
of the ceramic glow ac
plugs, they should be renewed without exception.
ce
e
nl
pt
du
an
Damaged ceramic glow plugs (e.g. heater pin of the glow plug
itte
y li
erm
is damaged) will invariably cause engine damage.
ab
ility
ot p
If the heater pin of the glow plug is damaged, the fragments
wit
, is n
must be removed from the combustion chamber before the
h re
hole
next starting of the engine, otherwise this will invariably cause
spec
satelettronica
mechanical damage.
es, in part or in w
t to the co
Do not oil or grease thread of cylinder head bore or of ceramic
glow plug.
rrectness of i
It is not permissible to install a combination of ceramic and
metallic glow plugs.
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Removing
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– Move lock carrier to service position ⇒ General body repairs,
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Note
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If only glow plug 1 - Q10- or glow plug 5 - Q14- are removed, the rig ht
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intake manifold does not need to be removed. co Vo
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Vehicles with engine codes BNZ and BPC:

Continued for all vehicles:
– Clean area around glow plug.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
port, let it work in briefly, and blow out with compressed air.
♦ Then use a cloth moistened with oil to clean the glow plug port.
– Pull connectors off glow plugs.

– Remove glow plugs -Q10- / -Q14- using U/J extension and
socket, 10 mm - 3220- .
1. Glow plug system 155

Distinguishing characteristics of glow plugs:

Glow plug Colour code
Ceramic glow plug white
Metal glow plug red, black or green
Installing
– Before installing, completely remove any deposits from the
cylinder head bore and thread, no soiling may fall into the cyl‐
inder.
– Always perform a test on all glow plugs after their installation
and before initial start of the cold engine ⇒ Vehicle diagnostic
tester.
Specified torques
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 126
1.2 Checking glow plugs -Q10- / -Q14-

satelettronica
♦ Hand multimeter - V.A.G 1526 E-
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♦ Adapter set - V.A.G 1594C-

hole
spec
es, in part or in w
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rrectness of i
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♦ Voltage tester - V.A.G 1527B-
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♦ Vehicle diagnostic tester auth or
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Caution
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Ceramic glow plugs are sensitive to knocks and bending. For
pe
ility
this reason a glow plug which has dropped from a small height
ot
wit
, is n
(approx. 2 cm) must not be used. Even if no damage is appa‐
h re
rent. It is absolutely necessary to follow the installation instruc‐
hole
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spec
tions, otherwise the heater pin of the glow plug can break and
es, in part or in w
cause engine damage.
t to the co
Transport and store only in original packaging or packed sep‐
arately in bubble wrap.
rrectness of i
Only remove ceramic glow plugs from their packaging imme‐
l purpos
diately before installing them.

If there is any doubt as to the condition of the ceramic glow
nform
ercia
plugs, they should be renewed without exception.

m
a
Damaged ceramic glow plugs (e.g. heater pin of the glow plug
com
tion in
is damaged) will invariably cause engine damage.
r
te o
thi
If the heater pin of the glow plug is damaged, the fragments
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iva
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r
must be removed from the combustion chamber before the

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next starting of the engine, otherwise this will invariably cause

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mechanical damage.
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Do not oil or grease thread of cylinder head bore or of ceramic
gh ht
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glow plug.
co Vo
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Prote AG.
It is not permissible to install a combination of ceramic and
metallic glow plugs.
Note
♦ The glow plug system is comprised of the automatic glow pe‐

riod control unit - J179- and the glow plugs.
♦ The diagnostics of the automatic glow period control unit -
J179- is carried out using the ⇒ Vehicle diagnostic tester. It is
possible that event entries have been saved to the engine
control unit - J623- .
♦ The automatic glow period control unit - J179- detects a de‐
fective glow plug.
♦ In addition to the check using the ⇒ Vehicle diagnostic tester
the glow plugs can be checked for continuity when installed or
removed.

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Transporter 2004 ➤ byV ua
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5-cylinder diesel engine - Edition 03.2018 tho tee
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Checking glow plugs using the ⇒ Vehicle diagnostic tester when
ce
le
un
pt
glow plugs are installed:
an
d
itte
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Conditions for testing
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ility
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• Battery voltage at least 11.5 V
wit
is n
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ole,
• Fuse for glow plugs OK.
spec
• Automatic glow period control unit - J179- OK
t to the co
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition.
rrectne
– Check engine control unit - J623- for event entries reference
s
glow plugs using Guided Fault Finding .
s o
cial p
f i
– If necessary, existing event entries should be checked and
nform
rectified using Guided Fault Finding .
mer
atio
m
– If no event entries exist the glow plugs are OK.

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n
c
i
or
n thi
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In addition a continuity test can be carried out on the glow plugs.

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sd
iva
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pr
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Continuity test on an installed glow plug:
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Note
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Not all faults on a glow plug can be detected using this test.
agen
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Conditions for testing

• Battery voltage at least 11.5 V
• Ignition off
• Fuse for glow plugs OK.
• Automatic glow period control unit - J179- OK
– Pull connectors off glow plugs.
– Connect voltage tester - V.A.G 1527B- cable to battery posi‐
tive (+), using clips from auxiliary measuring set - V.A.G
1594C- .
– Place test probe of voltage tester - V.A.G 1527B- on each glow
plug one after the other.
♦ Diode lights up: glow plug OK
♦ If LED does not light up: fit new glow plug
Continuity test on a removed glow plug:
– Connect wire of hand-held multimeter - V.A.G 1526 E- to rel‐
evant glow plug using auxiliary clips from auxiliary measuring
set - V.A.G 1594C- .
– Apply test probe of hand-held multimeter - V.A.G 1526 E- to
earth of glow plug and check for continuity.
– Repeat test for all glow plugs.
1.3 Removing and installing engine speed

sender - G28-

Removing
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– Remove noise insulation. olksw
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– Remove front torque reaction support
orise ⇒ page 15 . nte
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– Remove engine assembly mounting
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⇒ page 15 . c
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Note
erm
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♦ Do not release any lines from the air conditioner compressor.
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♦ Do not release any hoses from the power steering vane pump.
hole
spec
es, in part or in w
t to the co
– Release air conditioner compressor and fasten with, for ex‐
ample, “cable tie” ⇒ Heating, air conditioning; Rep. gr. 87 ;
Removing and installing air conditioner compressor .
rrectness of i
– Only loosen power steering vane pump, and secure it e.g. with
l purpos
cable tie ⇒ Running gear, axles, steering; Rep. gr. 48 .

– Clean area surrounding engine speed sender - G28- using
nform
ercia
commercially available wire brush and, if necessary, com‐

pressed air.
m
at
om
io
– Detach connector from engine speed sender - G28- .

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in t
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e
– Unclip lines from engine speed sender - G28- .

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– Unscrew bolt -arrow- for engine speed sender - G28- . Pull out
engine speed sender - G28- .
Installing
– Install engine speed sender - G28- .
– Attach connector for engine speed sender - G28- .
– Clip lines for engine speed sender - G28- in place.
– Removing and installing vane pump for power assisted steer‐
ing ⇒ Running gear, axles steering; Rep. gr. 48 .
Rep. gr. 87 .
– Install engine assembly mounting ⇒ page 15 .
– Install front torque reaction support ⇒ page 15 .
– Install noise insulation.
– Read event memory ⇒ Vehicle diagnostic tester.
Specified torques
satelettronica
Engine speed sender - G28- 10 Nm
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Rep. gr.28 - Glow plug system Prote AG.

4 - Cylinder Injection Engine (2.0l Engine) (AXA)

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4 - Cylinder Injection Engine (2.0l Engine) (AXA)

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Service

Service Department. Technical Information

23 - Mixture preparation - injection

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Copyright © 2018 Volkswagen AG, Wolfsburg K0058980720

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.1 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2 Crankcase - attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4 Renewing seal for timing housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.5 Renewing alternator shaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.6 Removing and installing thread insert for tie bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.1 Assembly overview – valve timing housing cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

2.3 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.2 Basic settings for gear train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3 Crankshaft bearing cap identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.5 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.6 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.4 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

7 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

1.2 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

1.1 Engine number/engine data

Bore Diameter, 81.0 81.0 81.0 81.0 81.0

Stroke mm 95.5 95.5 95.5 95.5 95.5

Compression ratio 18.5 18.5 18.5 18.5 18.5

Firing order 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3 1-2-4-5-3

Charging yes yes yes yes yes

Charge air cooling yes yes yes yes yes

2.1 Safety precautions when using testers

2.2 Safety precautions when working on the

Danger of overheating due to incorrectly fitted cap.

♦ Tighten cap of coolant expansion tank until it engages.

Observe the following points during all installation work, in par‐

ticular in the engine compartment, due to the space limitations:

vated charcoal filter system, coolant and refrigerant, brake

fluid and vacuum) and electrical wiring in their original po‐

♦ Ensure that there is sufficient clearance to all moving or

2 Rep. gr.00 - Technical data

♦ Cooling system is pressurized when engine is warm. If nec‐

2.3 Safety regulations for working on fuel

er from a full or partly filled fuel tank the following must be

radial fan with a displacement greater than 15 m3/h can be

♦ Ensure that there is sufficient clearance to all moving or

be used during a road test:

♦ Test and measuring instruments must always be secured to

To prevent injuries to persons and/or destruction of the injection

4 Rep. gr.00 - Technical data

If a mechanical fault is found on the turbocharger, e.g. a de‐

following rules for cleanliness:

3.2 Rules for cleanliness when working on

3.3 Rules for cleanliness when working on

When working on the fuel supply/injection system, carefully follow