Transcript Workshop Manual Service

Service
Workshop Manual
Transporter
2004 ➤
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Service Department. Technical Information
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Edition 04.2013
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00 - Technical data
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system
28 - Glow plug system
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20 - Fuel supply system
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19 - Cooling
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15 - Cylinder head, valve gear
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10 - Removing and installing engine
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Repair Group
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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
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 © 2013 Volkswagen AG, Wolfsburg
K0058981320
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine number, engine data . . . . . .e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Engine number, engine data V. o.lk.sw
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Safety instructions . . . o.ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . . . . . . . .
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Safety precautions when
au working on cooling system . . . . . . . . . . . . . r.ac. . . . . . . . . . . . . . . .
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Safety precautions when
working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . .
Rules for cleanliness when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
2
3
4
5
5
5
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
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1.2
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2
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1
1.1
2
2.1
2.2
2.3
3
3.1
3.2
1
Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Securing engine to assembly stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
11
12
14
14
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - poly V-belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
3
3.1
3.2
3.3
4
4.1
4.2
4.3
4.4
15
15
16
17
20
22
26
26
27
36
36
37
38
39
39
41
42
43
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2
2.1
2.2
2.3
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking delivery pressure of vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking for internal leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing toothed belt, vehicles ► 12.05 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing toothed belt, vehicles 01.06 ► . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents
44
44
47
53
56
57
60
62
64
64
65
73
i
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
3.1
3.2
3.3
3.4
3.5
4
4.1
Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Measuring axial clearance of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing valve stem seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
82
83
85
87
92
94
94
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AG. ..Vo. lk.sw. a.g.en.A. . . . . . . . 95
agen
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Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V.ol.ks.w. . . . . . . . . . . . . . . . . .e.s .no.t .g . . 95
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by
Assembly overview - sump and oil pump . . . . . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . .a.rant 95
ee
o
or
Removing and installing oil sump . . . . . . . . . .a.ut.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
ac
s
s
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Assembly overview - oil filter housing, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Assembly overview - oil supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Removing and installing oil supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
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Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant hose schematic diagram - engine codes AXB and AXC . . . . . . . . . . . . . . . . . . . .
Coolant hose schematic diagram - engine codes BRR and BRS . . . . . . . . . . . . . . . . . . . .
Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
106
106
107
108
111
113
113
114
116
118
118
119
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1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
3
3.1
3.2
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
1
1.1
1.2
2
2.1
3
3.1
4
4.1
4.2
5
5.1
Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing fuel cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel filter with fuel preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
122
122
124
127
127
128
128
129
129
130
132
132
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
1
1.1
1.2
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Contents
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Assembly overview - turbocharger, engine codes AXB and AXC . . . . . . . . . . . . . . . . . . . . 133
Assembly overview - turbocharger, engine codes BRR and BRS . . . . . . . . . . . . . . . . . . . . 135
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1
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.3
2
2.1
2.2
2.3
Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
137
139
139
140
141
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
1
1.1
1.2
1.3
1.4
2
2.1
2.2
2.3
3
3.1
4
4.1
4.2
5
5.1
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing O-rings for unit injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing prewiring for unit injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum system schematic diagram - engine codes AXB and AXC . . . . . . . . . . . . . . . . . .
Vacuum system schematic diagram - engine codes BRR and BRS, ► 2007 . . . . . . . . . . . .
Vacuum system schematic diagram - engine codes BRR and BRS, 2008 ► . . . . . . . . . . . .
Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - intake manifold, engine codes BRR and BRS . . . . . . . . . . . . . . . . . .
Assembly overview - intake manifold, engine codes AXB and AXC . . . . . . . . . . . . . . . . . .
Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
143
143
144
146
148
151
151
152
153
154
154
155
155
155
157
157
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Exhaust pipes, silencers . . . w. a.g.en. A. G
. ..V.o.lk.sw
. .ag. e.n.A.G.d.o.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
sn
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Assembly overview - silencers/catalytic
converters . . . o.t g. u.a. . . . . . . . . . . . . . . . . . . . . . . .
by
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Assembly overviewo-rissilencers/particulate
filter . . . . . . . . . . a.n.tee. . . . . . . . . . . . . . . . . . . . . .
h
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au pipes, silencers . . . . . . . . . . . . . . . . . . . . . .r a.c. . . . . . . . . . . . . . . . . . .
Separating exhaust
ss
Cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - cleansing exhaust emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly overview - exhaust gas recirculation, engine codes AXB and AXC . . . . . . . . . .
Assembly overview - exhaust gas recirculation, engine codes BRR and BRS . . . . . . . . . .
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1
1.1
1.2
1.3
2
2.1
2.2
3
3.1
3.2
158
158
159
160
162
162
163
167
167
168
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking metal glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
169
169
170
171
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1
1.1
1.2
1.3
Contents
iii
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Contents
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
00 –
Technical data
1
Engine number, engine data
(VRL005650; Edition 04.2013)
⇒ “1.1 Engine number, engine data”, page 1
1.1
Engine number, engine data
The engine number -arrow- (“engine code” and “serial number”)
can be found at the joint between engine and gearbox.
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
The engine code is also included on the vehicle data sticker.
Code letters
AXB
AXC
yes
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yes
01.06 ►
EU4
1.9
62/3500
200/2000
01.06 ►
EU4
1.9
75/3500
250/2000
79.5
79.5
95.5
95.5
18.0
18.0
51
51
1-3-4-2
1-3-4-2
yes
yes
yes
yes
yes (also availa‐ yes (also availa‐
ble without partic‐ ble without partic‐
ulate filter)
ulate filter)
yes
yes
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Charge air cooler
BRS
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Manufactured
03.03 ►
03.03 ►
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Emissions fulfil
EU3
EU3
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Capacity
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1.9
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Output
kW
at
rpm
77/3500
63/3500
u
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s
Torque s
Nm at rpm
250/2000
200/1600 …
2400
Bore
∅ mm
79.5
79.5
Stroke
mm
95.5
95.5
Compression ratio
18.0
18.0
CN
min.
51
51
Firing order
1-3-4-2
1-3-4-2
Exhaust gas recirculation
yes
yes
Turbocharger/supercharger
yes
yes
Particulate filter
no
no
BRR
1. Engine number, engine data
1
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Safety instructionswagen AG. Volkswagen AG doe
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system”,
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⇒ “2.1 Safety precautions wheneworking
on cooling system”, page
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2
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2.1
Safety precautions when working on
cooling system
WARNING
Steam may escape when expansion tank is opened. Wear eye
protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
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♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
2
Rep. gr.00 - Technical data
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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‐
sitions.
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⇒ “2.3 Safety precautions when working on injection system”,
page 4
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ss when working on fuel supply
⇒ “2.2 Safety precautions
page 3
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
♦ When the engine is warm, the cooling system is under pres‐
sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ For fitting spring-type clips, hose clamping pliers - VAS 6340-
or
♦ Hose clip pliers - VAS 6362- .
♦ 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).
♦ The arrows on the coolant pipes and on the ends of the hoses
must be aligned with each other.
2.2
Safety precautions when working on
fuel supply system
Note
n AG. Volkswagen AG do
♦ Hose connections are secured with quick-release
couplings,
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spring-type or clamp-type clips.
clips
only. The use of clamp or screw-type clips is not permissible.
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Always renew clamp-type clips with spring-type
clips.
tho
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ss
Fuel hoses on engine must be secured
with spring-type
♦ Spring-type clip pliers - VAS 5024A- or hose clip pliers - V.A.G
rrectness of i
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Caution
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1921- are recommended for installation of spring-type clips.
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ 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‐
sitions.
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
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♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
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♦ The fuel system is also under pressure! Before opening
the system, place cloths around the connections. Then
carefully loosen connection to release the pressure!
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♦ Ensure that there is sufficient clearance to all moving or
hot components.
Prote
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When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
2. Safety instructions
3
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Even before work commences, the extraction hose of an ac‐
tivated fume extraction system has to be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a
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!
2.3
Safety precautions when working on in‐
jection system
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ment, pay attention to the following due to the cramped condi‐
tions:
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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‐
sitions.
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WARNING
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u work, especially in the engine compart‐
When doing any repair
ac
a
ss
♦ Ensure that there is sufficient clearance to all moving or
hot components.
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
rear seat and operated by a second person from this location.
To prevent injuries to persons and/or destruction of the injection
and glow plug system, the following must be noted:
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♦ If the engine is to be turned at starter speed, without starting,
e.g. when checking compressions, disconnect unit injector
connector on cylinder head.
AG.
♦ Before disconnecting battery, obtain radio code for radios with
anti-theft coding.
♦ Disconnecting and connecting the battery must be done only
with the ignition switched off because the control unit for diesel
direction injection system could otherwise be damaged.
4
Rep. gr.00 - Technical data
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♦ The ignition must be switched off before connecting or dis‐
connecting injection or glow plug system wiring or tester ca‐
bles.
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♦ If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there
is a possibility that the person sitting in this seat may receive
serious injuries when the airbag is triggered.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Repair instructions
⇒ “3.1 Rules for cleanliness when working on fuel supply system/
injection system”, page 5
⇒ “3.2 Rules for cleanliness when working on charge air system”,
page 5
3.1
Rules for cleanliness when working on
fuel supply system/injection system
When working on the fuel supply and injection system, observe
the following “6 rules” for cleanliness:
♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
swagcomes
en AG into contact with the
AG. Volkfuel
♦ Also ensure thatwano
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does
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not must be cleaned
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immediately.
Damaged hoses must be renewed.
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3.2
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Rules for cleanliness when working on
charge air system
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When working on the turbocharger, pay careful attention to the
following rules for cleanliness:
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♦ Thoroughly clean all unions and surrounding areas before dis‐
connecting.
♦ Place removed parts on a clean surface and cover. Use only
lint-free cloths.
♦ Carefully cover opened components or seal if repairs cannot
be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have not been stored in their packing (e.g. in
tool boxes etc.).
♦ Existing transport and protective packaging and sealing caps
must only be removed immediately prior to installation.
do
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♦ When making repairs, remove oil from connection and hose
ends.
♦ When system is open: do not work with compressed air if this
can be avoided. Do not move vehicle unless absolutely nec‐
essary.
3. Repair instructions
5
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Removing and installing engine
1
Removing and installing engine
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⇒ “1.1 Removing engine”, page 6
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AG. Volkswagen AG d
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⇒ “1.2 Securing engine to assembly stand”, page 11
⇒ “1.3 Installing engine”, page 12
♦ Engine and gearbox sup‐
port - VW 540-
♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- VAS 6208-
6
Rep. gr.10 - Removing and installing engine
do
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♦ Workshop hoist - V.A.G
1202A- or workshop crane
- VAS 6100-
AG.
♦ Support clamp - VW 313-
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♦ Engine support - T10229with studs - T10229/1-
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♦ Lifting tackle - 2024 A-
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Removing engine
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1.1
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
1332♦ Engine and gearbox jack V.A.G 1383 A♦ Spring-type clip pliers VAS 5024A-
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♦ Stepladder - VAS 5085-
1. Removing and installing engine
7
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♦ Bracket - T10059-
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♦ Adapter - T10261-
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Transporter 2004 ➤
4-cylinder diesel engine - Edition
n AG. Volkswagen AG do
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04.2013
ss
♦ Before carrying out further work, disconnect battery earth
strap. For this reason, first check whether a coded radio is fit‐
ted. Obtain anti-theft code beforehand if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
Prote
cted
by
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.
– With ignition switched off, disconnect earth strap from battery.
– Remove connecting hoses -1- and -2- from air filter to turbo‐
charger and pressure regulating valve.
– Remove air filter housing with air mass meter and air duct
⇒ page 154 .
8
Rep. gr.10 - Removing and installing engine
AG.
♦ To avoid damage to lines/wiring, ensure sufficient clear‐
ance to all moving or hot components.
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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‐
sitions.
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When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
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Caution
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Unclip fuel supply and return lines at fuel filter -arrows-.
WARNING
♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system place a cloth around the connection. Release
pressure by carefully loosening the connection.
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
– Drain coolant ⇒ page 108 and detach coolant expansion tank.
– Remove connecting pipe -1- with connecting hoses between
charge air cooler and turbocharger.
– Remove poly V-belt ⇒ page 17 and tensioning element
⇒ Item 6 (page 15) .
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– Remove alternator ⇒ Electrical system; Rep.
olksgr. 27 ; Alter‐
V
y
nator; Removing and installing alternator
d b.
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– Remove front support mounting ofauttorque
s
⇒ page 14 .
s
To prevent damage to condenser or to refrigerant lines/hoses,
ensure that the lines and hoses are not stretched, kinked or bent.
To facilitate removing and installing engine without opening re‐
frigerant circuit:
– Remove air conditioner compressor ⇒ Heating, air condition‐
ing; Rep. gr. 87 ; Air conditioner compressor; Removing and
installing air conditioner compressor .
– Secure air conditioner compressor to body so that the refrig‐
erant lines are not under tension.
Continuation for all vehicles
– Remove connecting pipe between charge air cooler and intake
connection.
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– Remove belt pulley/vibration damper ⇒ page 15 .
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– Pull off or disconnect remaining electrical connections as nec‐
essary from engine and gearbox and move to one side.
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spec
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Vehicles with air conditioning system:
1. Removing and installing engine
9
AG.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Place adapter - T10261- on central bolt of rear torque reaction
support as shown. Unbolt torque reaction support from sup‐
port mounting.
– Remove right and left drive shafts ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shafts; Removing and installing
drive shaft .
– Remove front exhaust pipe ⇒ page 158 .
– Disconnect all connection, coolant, vacuum and intake hoses
from engine.
– Pull off or disconnect all other electrical connections as nec‐
essary from engine and gearbox and move to one side.
– Unclip line connector at hydraulic clutch slave cylinder
-arrow- (pull clip).
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
Selector mechanism .
– Unclip selector cable.
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– Screw stud - T10229/1- hand tight into thread -1- on cylinder
block.
Rep. gr.10 - Removing and installing engine
AG.
10
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Studs -1- must be secured to engine support - T10229- .
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– Attach engine support - T10229- to stud -1- screwed into the
hole in cylinder block. Attach engine support to stud T10229/1- with bolt M16×35/ 8.8 -2- and tighten to approx.
50 Nm.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Bolt engine support - T10229- to front of cylinder block
-arrows- with M12×25/ 8.8 bolts.
Specified torque
Component
Specified torque
Engine support - T10229- to
cylinder block
50 Nm
– Guide engine support - T10229- onto mounting pins -2- on
engine and gearbox jack - V.A.G 1383 A- . Raise engine
slightly.
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– Position engine for removal by turning the adjusting screwolkswage
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-1- to the zero-degree position.
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To remove securing bolts use a stepladder - VAS 5085- .
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– Unbolt gearbox side of assembly mounting first from body and
then from gearbox -arrows-.
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– Unbolt engine side of assembly mounting from above
-arrows-.
– Carefully lower engine with gearbox.
Note
Engine with gearbox must be guided carefully when lowering to
prevent damage to bodywork.
1.2
Securing engine to assembly stand
To carry out assembly work, engine must be secured to support
clamp - VW 540- of the assembly stand using engine and gearbox
support - VW 313- .
1. Removing and installing engine
11
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Procedure
– Unbolt gearbox.
– Attach lifting tackle - 2024 A- using shackle - T10059- as fol‐
lows and lift out of engine and gearbox jack - V.A.G 1383 Ausing workshop crane.
Belt pulley end: 4th hole in hook rail at position 1
Flywheel end: 3rd hole in hook rail at position 8
WARNING
The hooks and locating pins must be secured with locking pins.
Note
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♦ The positions marked 1…4 on the bar
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♦ The holes in the hook rails
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are
au counted
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– Secure engine to support clamp - VW 540- using engine and
gearbox support - VW 313- .
Installing engine
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spec
at
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his
1.3
Installation is carried out in the reverse order; note the following:
– Check clutch release bearing for wear and, if necessary, re‐
place (gearbox removed).
– Lightly grease input shaft splines with grease ⇒ Electronic
Part Catalogue (ETKA) (gearbox separated).
– Check whether dowel sleeves for centring engine with gear‐
box are in cylinder block and install if necessary (gearbox
removed).
– Align engine mountings stress-free by rocking, if necessary
loosen the engine mountings on the body.
Prote
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Rep. gr.10 - Removing and installing engine
AG.
12
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– Install engine side of assembly mounting from above
-arrows- using new bolts..
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– Install engine with engine support - T10229- in the zero-de‐
gree position.
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Procedure
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Install gearbox side of assembly mounting first to gearbox and
then to body -arrows- using new bolts.
– Install drive shafts ⇒ Running gear, axles, steering; Rep. gr.
40 ; Drive shafts; Removing and installing drive shaft .
– Install front exhaust pipe ⇒ page 158 .
– Connect line with plug-in connector to slave cylinder of hy‐
draulic clutch.
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– Install gear selector mechanism ⇒ Rep.
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mechanism .
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– Attach (clipped) gear selectoraucable.
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Install front support mounting with torque reaction support
⇒ page 14 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install poly V-belt ⇒ page 17 .
– Install tensioning element ⇒ Item 6 (page 15) .
– Install noise insulation, if removed ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body, front; Noise insulation .
– Replenish coolant ⇒ page 108 .
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fo
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
AG.
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♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 15
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Specified torques
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– Carry out road test and read event memory ⇒ Vehicle diag‐
nostic tester.
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s
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i
t to the co
n
form
spec
atio
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– Place adapter - T10261- on central bolt of torque reaction
support as shown. Tighten torque reaction support to support
mounting.
♦ ⇒ “3.1 Assembly overview - air filter”, page 154
♦ ⇒ “1.2 Assembly overview - silencers/particulate filter”,
page 159
♦ ⇒ “1.1 Assembly overview - silencers/catalytic converters”,
page 158
♦ Drive shafts; Assembly overview - drive shafts ⇒ Rep. gr. 40 ;
Assembly overview - drive shafts .
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
1. Removing and installing engine
13
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 14
2.1
Assembly overview - assembly mount‐
ings
Engine assembly mountings
Specified torque
Component
Specified torque
Bolt -A- (renew)
Bolt -B- (renew)
50 Nm + 90°
50 Nm + 90°
Front support mounting with torque reaction support
Specified torque
Specified torque
Bolt -A- (renew)
Bolt -B- (renew)
Bolt -C- (renew)
50 Nm + 90°
20 Nm +45°
90 Nm +180°
Rear support mounting with torque reaction support
Component
Bolt -A- (renew)
Bolt -B- (renew)
14
Specified torque
50 Nm + 90°
50 Nm +45°
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Specified torque
Rep. gr.10 - Removing and installing engine
AG.
Gearbox assembly mounting
20 Nm +180°
20 Nm + 90°
50 Nm + 90°
50 Nm +180°
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Bolt -A- (renew)
Bolt -B- (renew)
Bolt -C- (renew)
Bolt -D- (renew)
Specified torque
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Component
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Specified torque
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Component
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
13 –
Crankshaft group
1
Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 15
⇒ “1.2 Assembly overview - crankcase”, page 16
⇒ “1.3 Removing and installing poly V-belt”, page 17
⇒ “1.4 Renewing crankshaft oil seal - belt pulley end”,
page 20
⇒ “1.5 Removing and installing sealing flange on pulley end”,
page 22
1.1
Assembly overview - poly V-belt drive
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing and installing
⇒ page 17 .
2 - Bolt
❑ 10 Nm + 90°
3 - Cover
4 - Belt pulley and vibration
damper
❑ Can only be installed in
one position. Holes are
offset.
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5 - Bolt
❑ 25 Nm
rrectness of i
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nform
spec
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7 - Alternator
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6 - Poly V-belt tensioning
ment
❑ Swing with open-end
spanner to slacken poly
V-belt ⇒ page 17
8 - Bracket for ancillaries
9 - Bolt
❑ Observe tightening se‐
quence ⇒ page 17 .
❑ 45 Nm
10 - Banjo bolt
❑ 30 Nm
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12 - Pressure line
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11 - Seal
❑ Renew after removing.
13 - Vane pump
❑ Removing and installing ⇒ Running gear, axles and steering; Rep. gr. 48 ; Steering
1. Cylinder block (pulley end)
15
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
14 - Belt pulley
Assembly overview - crankcase
8 - Engine speed sender G28❑ Removing and instal‐
ling, engine codes BRR
and BRS ⇒ page 170 .
9 - Connection
❑ For thermostat.
10 - Bolt
❑ 15 Nm
11 - O-ring
❑ Renew after removing.
12 - Thermostat
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 85 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7 mm.
❑ Note installation position ⇒ page 116 .
❑ Removing and installing ⇒ page 116 .
13 - Bolt
❑ Observe tightening sequence ⇒ page 17 .
❑ 45 Nm
14 - Bracket
❑ Observe tightening sequence ⇒ page 17 .
16
Rep. gr.13 - Crankshaft group
thi
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7 - Bolt
❑ 15 Nm
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6 - Bolt
❑ Renew after removing.
❑ First fit upper left and
lower right bolts and
then tighten all 4 bolts in
diagonal sequence.
❑ 15 Nm + 90°
AG.
5 - Oil filter bracket
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4 - Bolt
❑ 15 Nm
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wit
3 - Gasket
❑ Renew after removing.
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2 - Bracket
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1 - Cylinder block
❑ Removing and installing
crankshaft
⇒ page 36 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 39 .
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1.2
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
15 - Poly V-belt tensioning element
16 - Bolt
❑ 25 Nm
17 - Oil sump
❑ Clean sealing surface before fitting.
❑ With Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
18 - Bolt
❑ 15 Nm
Sequence for tightening ancillary bracket to cylinder block
– Place ancillary bracket on cylinder block (observe dowel
sleeve between ancillary bracket and cylinder block).
– Tighten ancillary bracket as shown in following tightening se‐
quence:
1-
Tighten bolt -A- to 45 Nm
2-
Tighten bolt -B- to 45 Nm
3-
Tighten bolt -C- to 45 Nm
4-
Tighten bolt -D- to 45 Nm
5-
Tighten bolt -E- to 45 Nm
6-
Tighten bolt -F- to 45 Nm
1.3
Removing and installing
poly V-belt
Volkswa
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Special tools and workshop
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Removing
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– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
rrectness of i
t to the co
nform
spec
a
t
i
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♦ Locking pin - T10060
Aho
1. Cylinder block (pulley end)
17
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.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove connecting pipe -1- with connecting hoses between
charge air cooler and turbocharger.
– Mark direction of rotation of poly V-belt.
– To slacken poly V-belt, swivel tensioning element in direction
of arrow (using, for example, 16 mm open-end spanner).
– Lock tensioning element using locking pin - T10060 A- .
– Remove poly V-belt.
Installing
Installation is carried out in the reverse order; note the following:
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Before installing poly
ut V-belt, ensure that all sub-assemblies
ra
a
c
s
(alternator, air conditioner
compressor
and
vane
pump)
are
s
Note
♦
un
le
proper seating of belt in belt pulleys.
♦ For vehicles without air conditioning, put poly V-belt over al‐
ternator last.
♦ For vehicles with air conditioning, put poly V-belt over air con‐
ditioner compressor last.
– Remove locking pin - T10060 A- .
After completing repair, always:
AG.
Rep. gr.13 - Crankshaft group
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18
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– Start engine and check that belt runs properly.
rrectne
s
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i
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form
spec
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♦ When fitting poly V-belt, check direction of belt rotation and
ility
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ce
securely mounted.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Belt drive without air conditioner compressor
Belt drive with air conditioner compressor
Specified torques
♦ ⇒ “2.1 Assembly overview - charge air system”, page 139
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♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
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AG.
1. Cylinder block (pulley end)
19
Prote
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by
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.4
Renewing crankshaft oil seal - belt pulley end
Special tools and workshop
equipment required
♦ Counterhold tool - 3099♦ Oil seal extractor - 3203♦ Assembly tool - T10053♦ Torque wrench - V.A.G
1331-
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Removing:
– Removing toothed belt (for vehicles ► 12.05) ⇒ page 65 .
AG.
Prote
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Rep. gr.13 - Crankshaft group
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20
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– Removing toothed belt, (for vehicles 01.06 ►) ⇒ page 73 .
rrectne
s
s
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f
i
t to the co
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form
spec
atio
h re
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thi
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♦ Torque wrench - V.A.G
1332-
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3099- .
Note
♦ When bolting on counterhold, remove one securing bolt from
sump.
♦ When bolting on counterhold, place two washers between
toothed belt pulley and counterhold.
– To guide oil seal extractor - 3203- , screw centre bolt into
crankshaft by hand to stop.
– Unscrew inner part of oil seal extractor - 3203- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor.
– Position oil seal extractor - 3203- and screw forcibly as far as
possible into oil seal.
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ss the reverse order; note the following:
Installation is carried out in
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
– Fit guide sleeve - T10053/1- onto crankshaft journal.
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– Installing, tensioning toothed belt (for vehicles ► 12.05)
⇒ page 65 .
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– Using press sleeve - T10053- , press in onto stop with central
bolt.
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– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
nal.
AG.
– Installing, tensioning toothed belt (for vehicles 01.06 ►)
⇒ page 73 .
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
1. Cylinder block (pulley end)
21
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.5
Removing and installing sealing flange on pulley end
Special tools and workshop
equipment required
♦ Counterhold tool - 3099♦ Assembly tool - T10053♦ Torque wrench - V.A.G
1331-
olkswagen AG
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Removing
– Removing toothed belt, (for vehicles ► 12.05) ⇒ page 65 .
– Removing toothed belt, (for vehicles 01.06 ►) ⇒ page 73 .
22
Rep. gr.13 - Crankshaft group
rrectne
s
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form
spec
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♦ Silicone sealant ⇒authElec‐
tronic Parts Catalogue
(ET‐
ss
KA)
rrectness of i
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spec
atio
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wit
Note
♦ To fit the counterhold it is possible that 1 sump securing screw
must be removed.
♦ When bolting on counterhold, place two washers between
toothed belt pulley and counterhold.
– Drain off engine oil.
– Remove sump ⇒ page 96 .
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
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– Remove residual sealant on sealing flange using a rotating
plastic brush (wear eye protection).
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– Remove crankshaft toothed belt pulley. To do this, lock tooth‐
ed belt pulley using counterhold - 3099- .
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4-cylinder diesel engine
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a
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– Clean sealing surfaces. They must be free of oil and grease.
AG.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Observe use-by-date of sealant.
♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
♦ Sealant bead must not be wider than 2…3 mm because ex‐
cess sealant can otherwise enter sump and block strainer in
oil pump suction line or drip onto crankshaft oil seal.
♦ Before applying sealant bead, cover the sealing surface of the
sealing ring with a clean cloth.
– Cut off nozzle of tube at front marking (∅ of nozzle approx.
3 mm).
1. Cylinder block (pulley end)
23
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Apply silicone sealant bead as shown to clean sealing
c
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
ility
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–
– Fit sealing flange immediately and lightly tighten all bolts.
rrectness of i
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at
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his
Note
♦ When fitting sealing flange with oil seal installed use guide
sleeve - T10053/1- .
♦ Sealing compound must dry for approx. 30 minutes after in‐
stallation. Only then fill with engine oil.
– Tighten sealing flange securing bolts diagonally and alternate‐
ly.
– Install sump ⇒ page 96 .
Install toothed belt and adjust valve timing (for vehicles ► 12.05)
⇒ page 65 .
Prote
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♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
24
Rep. gr.13 - Crankshaft group
AG.
♦ ⇒ “1.1 Assembly overview - sump and oil pump”, page 95
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
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Specified torques
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Install toothed belt and adjust valve timing (for vehicles 01.06 ►)
⇒ page 73 .
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2. Cylinder block, gearbox end
25
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Cylinder block, gearbox end
⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 26
⇒ “2.2 Removing and installing sealing flange on gearbox side”,
page 27
⇒ “2.2.1 Pressing out sealing flange with sender wheel”,
page 28
⇒ “2.2.2 Pressing in sealing flange with sender wheel”,
page 29
⇒ “2.2.3 A - Fit seal with sender wheel on assembly tool T10134
”, page 30
⇒ “2.2.4 B - Fit assembly tool T10134 with sealing flange on
crankshaft flange”, page 31
⇒ “2.2.6 D - Pressing sender wheel onto crankshaft flange using
assembly tool T10134 ”, page 33
Prote
cted
by
2.1
Assembly overview - cylinder block, gearbox end
1 - Seal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renew. ⇒ page 20 .
2 - Sealing flange
❑ Must seat on dowel
sleeves.
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
❑ Removing and installing
⇒ page 22 .
3 - Cylinder block
❑ Removing and installing
crankshaft
⇒ page 36 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 39 .
4 - Bolt
❑ Renew after removing.
❑ 60 Nm + 90°
5 - Flywheel
❑ When removing and in‐
stalling, lock with coun‐
terhold - T10044- and
26
AG.
⇒ “2.2.8 F - Re-pressing sender wheel”, page 34
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⇒ “2.2.7 E - Checking sender wheel installation position on crank‐
shaft”, page 33
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⇒ “2.2.5 C - Bolting assembly tool T10134 onto crankshaft flange”,
page 32
Rep. gr.13 - Crankshaft group
rrectne
s
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form
spec
atio
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Transporter 2004 ➤
h
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4-cylinder diesel engine
ss - Edition 04.2013
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
sleeve - T10044/1- .
6 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
7 - Bolt
❑ 15 Nm
8 - Sealing flange with oil seal
Engine codes BRR and BRS:
❑ Renew complete with oil seal and sender wheel only.
❑ Renew. ⇒ page 27 .
Engine codes AXB and AXC:
❑
❑
❑
❑
❑
Renew complete only.
Do not additionally oil or grease the oil seal sealing lip.
Before installing, remove oil residue from crankshaft journal using a clean cloth.
Use support sleeve supplied when installing.
Only remove supporting sleeve after sealing flange has been slid onto crankshaft journal.
9 - Engine speed sender - G28❑ In crankcase for engine codes AXB and AXC ⇒ Item 8 (page 16) .
❑ Removing and installing, engine codes BRR and BRS ⇒ page 170 .
❑ 5 Nm
2.2
Removing and installing sealing flange
on gearbox side
Special tools and workshop equipment required
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♦ Assembly tool - T10134-
rrectness of i
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at
i
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♦ Torque wrench - V.A.G 1331-
do
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2. Cylinder block, gearbox end
27
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
pe
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Not illustrated:
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♦ Socket - V.A.G 1332/11-
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♦ Vernier gauge
♦ 3 hexagon bolts M6 x 35 mm
♦ 2 hexagon bolts M7 x 35 mm
2.2.1
Pressing out sealing flange with sender
wheel
Note
♦ For the sake of clarity, the work is performed with the engine
removed.
Prote
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– Remove intermediate plate.
– Set engine to TDC for No. 1 cylinder, Removing, installing and
tensioning toothed belt (for vehicles ► 12.05) ⇒ page 65 .
agen
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AG.
– Set engine to TDC for No. 1 cylinder, Removing, installing and
tensioning toothed belt (for vehicles 01.06 ►) ⇒ page 73 .
– Remove sump ⇒ page 96 .
– Remove engine speed sender - G28- -arrow- using a com‐
mercially available ball-ended hex key socket.
– Unscrew securing bolts of sealing flange.
Note
Sealing flange and sender wheel are pressed off the crankshaft
together using 3 M6 x 35 mm bolts.
28
Rep. gr.13 - Crankshaft group
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– Remove flywheel.
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removed.
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♦ The procedure is identical whether the engine is installed or
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Screw 3 M6 x 35 mm bolts into threaded holes of sealing flange
-arrows-.
– Screw bolts alternately (max. 1/2 turn (180°) for each bolt) into
sealing flange and press sealing flange off crankshaft together
with sender wheel.
2.2.2
Pressing in sealing flange with sender
wheel
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing
lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
sembly device - T10134- by a locating pin.
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♦
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♦
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Sealing flange and sender wheel must not be separatedd bor
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The sender wheel is held in its installation position
ss on the as‐
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel.
rrectness of i
t to the co
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spec
at
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his
♦ The assembly device - T10134- is held in its position relative
to the crankshaft by a guide pin inserted into a hole in the
crankshaft.
Assembly tool - T10134A - Clamping surface
B - Hexagon nut
C - Assembly housing
D - Locating pin
E - Hexagon socket head bolt
F - Guide pin for diesel engines (black knob)
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2. Cylinder block, gearbox end
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G - Guide pin for petrol engines (red knob)
29
Prote
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2.2.3
A - Fit seal with sender wheel on as‐
sembly tool - T10134-
– Screw on hexagon nut -B- until just before it touches clamping
surface -A- of threaded spindle.
– Clamp assembly device - T10134- in a vice on clamping sur‐
face -A- of threaded spindle.
– Press the assembly housing -C- downwards until it lies on
hexagon nut -B-, -arrow-.
Note
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Inner part of assembly tool and assembly
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– Remove securing clip -arrow- from new sealing flange.
rrectness of i
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spec
atio
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wit
Note
The sender wheel must not be taken out of the sealing flange or
twisted.
– Locating hole -A- on sender wheel -C- must align with marking
-B- on sealing flange.
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Rep. gr.13 - Crankshaft group
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30
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– Place sealing flange with front side facing down on a clean
level surface.
rrectness of i
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spec
at
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his
– Upper edge of sender wheel and front edge of sealing flange
must align -arrows-.
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– Push sealing lip support ring -A- downwards in direction of ar‐
row until it lies on flat surface.
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Transporter 2004 ➤
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4-cylinder
diesel
- Edition 04.2013
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– Place sealing flange with front side facing downwards onto
assembly tool - T10134- so that locating pin -B- can be inser‐
ted in sender wheel hole -A-.
Note
Ensure sealing flange lies flat on assembly tool.
– Push sealing flange and support ring for sealing lip -B- against
surface of assembly tool - T10134- whilst tightening the 3
knurled screws -A- so that locating pin cannot slide out of
sender wheel hole.
Note
When installing sealing flange, ensure that sender wheel remains
fixed in assembly device.
2.2.4
B - Fit assembly tool - T10134- with seal‐
ing flange on crankshaft flange
•
Crankshaft flange must be free of oil and grease.
•
Engine positioned at TDC No. 1 cylinder.
2. Cylinder block, gearbox end
31
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Screw hexagon nut -B- on until it reaches end of threaded
spindle.
– Press threaded spindle of assembly tool - T10134- in direction
of arrow, until hexagon nut -B- lies against assembly housing
-A-.
– Align flat side of assembly housing to crankcase's sealing sur‐
face on the oil sump side.
– Secure assembly tool - T10134- to crankshaft flange with hex‐
agon socket head bolts -A-.
Note
Screw hexagon socket head bolts -A- into crankshaft flange (ap‐
prox. 5 full turns).
2.2.5
C - Bolting assembly tool - T10134- onto
crankshaft flange
– Push assembly housing -C- by hand in direction of arrow until
sealing lip support ring -B- touches crankshaft flange -A-.
r
fo
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– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against assembly housing -C-.
32
Rep. gr.13 - Crankshaft group
Prote
cted
by
– Tighten the two hexagon socket head bolts of the assembly
tool hand-tight.
AG.
The guide pin for petrol engines (red knob) -F- must not be inser‐
ted in threaded hole of crankshaft.
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Note
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– Push guide pin for diesel engines (black knob) -D- into hole in
crankshaft. This ensures that the sender wheel reaches its fi‐
nal installation position.
rrectne
s
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f
i
t to the co
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form
spec
atio
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ole,
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– To guide sealing flange into cylinder block, screw
35 mm bolts -A-.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2.2.6
D - Pressing sender wheel onto crank‐
shaft flange using assembly tool T10134-
– Tighten hexagon nut of assembly tool - T10134- using torque
wrench - V.A.G 1331- and 24 mm flared ring spanner tool in‐
sert - V.A.G 1332/11- .
Specified torque
Component
Specified torque
Hexagon nut of assembly tool T10134-
35 Nm
Note
After hexagon nut is tightened a small air gap must still be present
between cylinder block and sealing flange.
2.2.7
E - Checking sender wheel installation
position on crankshaft
wagthe
Volksof
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– Screw on the hexagon nut -E- until it reaches
the
AG. end
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– Unscrew 2 bolts -A- from cylinder
or block.
h
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ac
– Remove assembly tool - T10134- .
– Remove sealing lip support ring.
rrectness of i
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spec
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wit
– The sender wheel is in the correct installation position on the
crankshaft if a gap -a- = 0.5 mm exists between crankshaft
flange -A- and sender wheel -B-.
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– Unscrew the three knurled sscrews
-B- out of sealing flange.
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2. Cylinder block, gearbox end
33
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Place caliper gauge on crankshaft flange.
– Measured distance -a- between crankshaft flange and sender
wheel.
If dimension -a- is too small:
– Re-press sender wheel ⇒ page 34 .
If dimension -a- is achieved:
– Tighten new sealing flange securing bolts diagonally and al‐
ternately.
– Install engine speed sender - G28- -arrow- and tighten secur‐
ing bolt.
– Install sump ⇒ page 96 .
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– Install intermediate plate.
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F - Re-pressing sender wheel
– Secure assembly tool - T10134- to crankshaft flange with hex‐
agon socket head bolts -A-.
– Tighten the two hexagon socket head bolts hand-tight.
– Screw hexagon nut -E- onto threaded spindle by hand until it
lies against assembly housing -C-.
AG.
Rep. gr.13 - Crankshaft group
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34
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– Push the assembly tool - T10134- against the sealing flange
by hand.
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spec
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2.2.8
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– Install flywheel
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Tighten hexagon nut of assembly tool - T10134- using torque
wrench - V.A.G 1331- and 24 mm flared ring spanner tool in‐
sert - V.A.G 1332/11- .
Specified torque
Component
Specified torque
Hexagon nut of assembly tool T10134-
40 Nm
– Check the sender wheel installation position on crankshaft
again ⇒ page 33
If dimension -a- is too small again:
– Tighten hexagon nut of assembly tool - T10134- .
Specified torque
Component
Specified torque
Hexagon nut of assembly tool T10134-
45 Nm
– Check the sender wheel installation position on crankshaft
again ⇒ page 33
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
26
♦ ⇒ “1.1 Assembly overview - sump and oil Apump”,
page 95
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♦
2. Cylinder block, gearbox end
35
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 36
⇒ “3.2 Removing and installing sender wheel”, page 37
⇒ “3.3 Crankshaft dimensions”, page 38
3.1
Assembly overview - crankshaft
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.
1 - Bearing shells 1, 2, 4 and 5
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
❑ Do not interchange
used bearing shells
(mark).
un
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Rep. gr.13 - Crankshaft group
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36
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6 - Sender wheel
❑ Only engine codes AXB and AXC
❑ For engine speed sender - G28- .
❑ Renew if damaged.
do
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5 - Thrust washer
❑ For bearing cap 3.
❑ Note fixing arrange‐
ment.
rrectness of i
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spec
a
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wit
thi
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4 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove.
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3 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
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2 - Bolt
❑ Renew after removing.
❑ To measure radial clear‐
ance, tighten to 65 Nm
but not further.
❑ 65 Nm + 90°
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑ Always renew sender wheel if securing bolts have been unscrewed.
❑ Removing and installing ⇒ page 37 .
7 - Bolt
❑ Only engine codes AXB and AXC
❑ Renew after removing.
❑ 10 Nm + 90°
8 - Dowel pin
❑ Only engine codes AXB and AXC
❑ Check projection from crankshaft ⇒ page 37
9 - Crankshaft
❑ Axial clearance, new: 0.07…0.17 mm; wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage , new: 0.03…0.08 mm; wear limit: 0.17 mm.
❑ Do not rotate crankshaft when checking radial clearance.
❑ Crankshaft dimensions ⇒ page 38 .
10 - Thrust washer
❑ For cylinder block, bearing 3.
3.2
Removing and installing sender wheel
Special tools and workshop equipment required
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♦ Depth gauge
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– Always renew sender wheel -2- each time bolts -1- are loos‐
ened.
Specified torques
♦ ⇒ “3.1 Assembly overview - crankshaft”, page 36
do
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The second time the bolts are tightened, the contact points in the
sender wheel for the countersunk heads are deformed so far that
the bolt heads seat on the crankshaft -3-, -arrows- and the sender
wheel is loose under the bolts.
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Note
3. Crankshaft
37
AG.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Checking dowel pin projection out of crankshaft
Test procedure
– Use depth gauge to check dowel pin projection -a- with sender
wheel -1- removed.
1 - Sender wheel
2 - Securing bolt
3 - Projection of dowel pin -3- out of crankshaft a = 2.5…3.0 mm
3.3
Crankshaft dimensions
(Dimensions in mm)
Crankshaft bearing
journal ∅
-0.022
-0.042
47.80
-0.022
-0.042
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Rep. gr.13 - Crankshaft group
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38
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Basic dimension 54.00
Conrod
journal ∅
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Honing dimen‐
sion
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
4
Pistons and conrods
⇒ “4.1 Assembly overview - pistons and conrods”, page 39
⇒ “4.2 Measuring piston projection at TDC”, page 41
⇒ “4.3 Checking piston and cylinder bore”, page 42
⇒ “4.4 Piston and cylinder dimensions”, page 43
Assembly overview - pistons and conrods
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2 - Piston
❑ With combustion cham‐
ber.
❑ Mark installation posi‐
tion and cylinder num‐
ber.
❑ Arrow on piston crown
points to belt pulley end.
❑ Install using piston ring
clamp.
❑ If piston skirt is cracked,
renew piston.
❑ Installation position and
allocation of piston to
cylinder ⇒ page 43 .
❑ Checking piston projec‐
tion at TDC
⇒ page 41 .
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1 - Piston rings
❑ Offset gaps by 120°.
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 40 .
❑ Checking ring-to-groove
clearance ⇒ page 41 .
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4.1
3 - Piston pin
❑ If difficult to remove,
heat piston to 60 °C.
❑ Remove and install us‐
ing drift - VW 222 A- .
4 - Circlip
5 - Conrod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
6 - Bearing shell
❑ Note installation position.
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
4. Pistons and conrods
39
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑
❑
❑
❑
Check for secure seating.
Axial clearance, wear limit: 0.37 mm
Check radial clearance with Plastigage; wear limit: 0.08 mm.
Do not rotate crankshaft when checking radial clearance.
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 42 .
❑ Piston and cylinder dimensions ⇒ page 43 .
8 - Conrod bearing cap
❑ Note installation position.
❑ Due to the cracking method used to separate the bearing cap from the conrod in manufacture, the caps
only fit in one position and only on the appropriate conrod.
9 - Oil spray jet
❑ For piston cooling.
10 - Bolt
❑ Insert without sealant.
❑ 25 Nm
ss
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11 - Conrod bolt
❑ Renew after removing. AG. Volkswagen
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❑ Use old bolt
ir sefor measuring radial clearance.
tee
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❑ 30 Nm a+u 90°
ac
Special tools and workshop equipment required
– Insert ring at right angles from above and push down into cyl‐
inder approx. 15 mm from bottom end of cylinder.
Prote
cted
by
Rep. gr.13 - Crankshaft group
0.20 … 0.40
0.20 … 0.40
0.25 … 0.50
1.0
1.0
1.0
AG.
40
Wear limit
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1st compression ring
2nd compression ring
Oil scraper ring
New
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Piston ring
dimensions in mm
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♦ Feeler gauges
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spec
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Checking piston ring gap
es, in part or in w
l purpos
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Checking ring-to-groove clearance
rrectness of i
t to the co
nf
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m
spec
atio
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wit
Special tools and workshop equipment required
♦ Feeler gauges
Wear limit
0.06 … 0.09
0.05 … 0.08
0.03 … 0.06
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4.2
New
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1st compression ring
2nd compression ring
Oil scraper ring
thi
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– Clean annular groove before check.
Piston ring
dimensions in mm
Transporter 2004 ➤
diesel engine - Edition 04.2013
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AG. Volkswagen AG d
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a
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0.25
0.25
0.15
Measuring piston projection at TDC
Special tools and workshop equipment required
♦ Measuring tool - VW 382/7-
♦ Universal measuring tool - VW 385/17-
♦ Dial gauge
4. Pistons and conrods
41
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
AG. Volkswagen AG d
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Piston projection at TDC must be measured on all pistons
is when
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installing new pistons or a short engine. Install the appropriate
ut
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s
cylinder head gasket depending upon piston projection,
accord‐
s
Test procedure
rrectness of i
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spec
at
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Note
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ing to following table:
Turn engine over clockwise to measure piston projection at TDC.
Piston projection
0.91 mm … 1.00 mm
1.01 mm … 1.10 mm
1.11 mm … 1.20 mm
Cylinder head gasket identification
♦ Part no. = arrow 1
Identification
Holes/notches
1
2
3
♦ Production control code = arrow 2 (can be disregarded)
Checking piston and cylinder bore
Procedure
Checking cylinder bores
Special tools and workshop equipment required
♦ Cylinder gauge 50…100 mm
– Take measurements at 3 positions in both lateral direction
-A- and longitudinal direction -B-. Difference between actual
and nominal diameter max. 0.10 mm.
42
Rep. gr.13 - Crankshaft group
AG.
4.3
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If different values are determined during the projection measure‐
ment, use the largest dimension for selecting the gasket.
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Note
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♦ Holes = arrow 3
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
The cylinder bores must not be measured when the cylinder block
is mounted on assembly stand, as measurements may then be
incorrect.
Piston installation position and allocation of piston to cylinder
Piston in cylinders 1 and 2:
Larger intake valve chamber towards flywheel -arrowsPiston in cylinders 3 and 4:
Larger intake valve chamber towards belt pulley end -arrowsNote
♦ New piston allocation to cylinders is shown by a coloured
marking on piston crown.
♦ Piston for cylinders 1 and 2: marked 1/2
♦ Piston for cylinders 3 and 4: marked 3/4
4.4
Piston and cylinder dimensions
AG. Volkswagen AG d
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Cylinder
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Basic dimen‐
mm
79.47
79.51
e
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s
Stage I
mm
79.72
79.76
r
fo
ng
80.01
rrectne
s
s
o
f
i
t to the co
n
form
spec
atio
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79.97
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Stage II
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Honing dimension
4. Pistons and conrods
43
Prote
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Transporter 2004 ➤
4-cylinder diesel engine - Edition. V04.2013
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Cylinder head, valve gear
1
Cylinder head
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15 –
⇒ “1.2 Removing and installing cylinder head”, page 47
rrectness of i
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⇒ “1.1 Assembly overview - cylinder head”, page 44
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⇒ “1.3 Removing and installing cylinder head cover”, page 53
⇒ “1.4 Checking compression”, page 56
⇒ “1.5 Removing and installing vacuum pump”, page 57
⇒ “1.6 Checking delivery pressure of vacuum pump”, page 60
⇒ “1.7 Checking for internal leaks”, page 62
1.1
Assembly overview - cylinder head
Prote
cted
by
5 - Bolt
❑ 100 Nm
6 - Camshaft pulley
7 - Hub
❑ With sender wheel
❑ Use counterhold tool T10051- to loosen and
tighten.
❑ To remove, use puller T10052- .
❑ Removing and installing
⇒ page 87 .
8 - Rear toothed belt guard
9 - Sealing grommet
❑ Renew if damaged.
44
Rep. gr.15 - Cylinder head, valve gear
AG.
4 - Bolt
❑ 25 Nm
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3 - Bolt
❑ Renew after removing.
❑ 10 Nm
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2 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning toothed
belt (for vehicles ►
12.05) ⇒ page 65 .
❑ Removing, installing
and tensioning toothed
belt (for vehicles 01.06
►) ⇒ page 73 .
do
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1 - Toothed belt guard upper
part
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
10 - Hall sender - G40❑ For camshaft position.
❑ To remove, unbutton sealing grommet ⇒ Item 9 (page 44) from rear toothed belt guard.
❑ Removing and installing ⇒ page 171 .
11 - Cylinder head bolt
❑ Renew after removing.
❑ Before installing, place washers in cylinder head ⇒ Item 4 (page 82) .
❑ Observe sequence when loosening and tightening ⇒ page 47 .
12 - Cylinder head cover
❑ Before fitting, thoroughly clean sealing surface of cylinder head with clean cloth.
❑ Removing and installing ⇒ page 53 .
13 - Connecting hose to turbocharger
14 - Pressure regulating valve
❑ For crankcase ventilation.
15 - Cap
❑ Renew seal if damaged.
16 - Seal
❑ Only engine codes AXB and AXC
❑ Renew if damaged.
pe
rm
itte
d
un
le
17 - Bolt
❑ Observe tightening sequence ⇒ page 53 .
❑ 10 Nm
20 - Lifting eye
es, in part or in w
l purpos
hole
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19 - Bolt
❑ 20 Nm
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18 - Gasket for cylinder head cover
❑ Renew if damaged.
❑ Before fitting, seal transitions with sealant ⇒ Electronic Parts Catalogue (ETKA) .
❑ Removing and installing ⇒ page 53 .
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25 - Supply hose
❑ White or with white marking.
❑ Check for secure seating.
❑ Clipped on fuel filter, identification -VM❑ From fuel filter ⇒ page 129 or ⇒ page 130
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24 - Vacuum pump
❑ For fuel and vacuum supply.
❑ Checking ⇒ page 60 .
❑ Removing and installing ⇒ page 57 .
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23 - From brake servo
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22 - Central connector
❑ For unit injector
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21 - Unit injector
❑ Removing and installing ⇒ page 146 .
26 - Return hose
❑ Blue or with blue marking.
❑ Check for secure seating.
1. Cylinder head
45
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑ Clipped on fuel filter, identification -RF❑ To fuel filter ⇒ page 129 or ⇒ page 130
27 - Gasket
❑ Renew after removing.
28 - Cylinder head
❑ After renewing, renew entire coolant.
❑ Removing and installing ⇒ page 47 .
29 - Cylinder head gasket
❑ Renew after removing.
❑ After renewing, renew entire coolant.
❑ Note marking ⇒ page 47 .
30 - Glow plug
❑ 15 Nm
❑ Removing and installing, checking ⇒ page 169
31 - Tensioning roller
32 - Nut
❑ 20 Nm +45°
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Special tools and workshop equipment required
♦ Straight edge
♦ Feeler gauges
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Rep. gr.15 - Cylinder head, valve gear
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46
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Max. permissible distortion: 0.1 mm.
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Checking cylinder head
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
Reworking diesel cylinder heads is not permissible.
Cylinder head gasket identification
♦ Part no. = arrow 1
♦ Production control code = arrow 2 (can be disregarded)
♦ Holes = arrow 3
Note
♦ Different thicknesses of cylinder head gasket are fitted de‐
pending on the piston projection. When renewing gasket,
install new gasket with same identification.
♦ Piston projection at TDC must be determined when installing
new pistons or a short engine ⇒ page 41 .
1.2
Removing and installing cylinder head
Note
From 01.06 a modified engine support has been introduced, it is
no longer necessary to remove the engine support and supporting
the engine for the procedure "Removing and installing cylinder
head".
-1-: Engine support ► 12.05 (removal necessary) ⇒ page 14
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-2-: Engine support 01.05 ► (removal not necessary).
1. Cylinder head
47
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Special tools and workshop
equipment required
♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- VAS 6208♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
1332♦ Hand vacuum pump V.A.G 1390♦ Water drainage container V.A.G 1390/1-
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Rep. gr.15 - Cylinder head, valve gear
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Only vehicles ► 12.05:
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spec
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♦ Retainer - T10014- (only
vehicles ► 12.05)
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Workshop hoist - V.A.G 1202A- or workshop crane - VAS
6100♦ Support bracket - 10 - 222 A- with adapter - 10 - 222 A /3- ,
adapter - 10 - 222 A /23- and adapter - 10 - 222 A /16- .
Note
All cable ties which are opened or cut through when cylinder head
is removed must be fastened in the same position when cylinder
head is installed.
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When doing any repair work, especially in
the
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a
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Caution
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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‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance to
all moving or hot components.
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.
AG.
Note
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♦ If the cylinder head is renewed, the coolant must also be com‐
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
– Drain coolant ⇒ page 108 .
WARNING
In extreme cases, the fuel lines and the fuel can reach a tem‐
perature of 100 °C on vehicles with unit injector engine. Allow
the fuel to cool down before disconnecting the lines - danger
of scalding.
Wear protective gloves and eye protection.
1. Cylinder head
49
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Disconnect fuel supply and return lines -arrows- at fuel filter.
– Before removing cylinder head extract fuel at vacuum pump
using hand vacuum pump - V.A.G 1390- and fluid receptacle
- V.A.G 1390/1- ⇒ page 57 .
– Pull vacuum connection off brake servo.
–
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Unbolt coolant expansion tank from lock carrier.
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Disconnect all connection, coolant, vacuum and intake ahoses
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– Remove front exhaust pipe ⇒ page 158 .
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– Remove cylinder head cover ⇒ page 44 .
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– Pull off or disconnect all electrical connections from cylinder
head as necessary and lay them to one side.
– Remove particulate filter (only engine codes BRR and BRS)
⇒ page 163 .
– Remove turbocharger support and oil return from turbocharg‐
er.
– Remove oil supply line and lay to side ⇒ page 103 .
– Removing, tensioning toothed belt (for vehicles ► 12.05)
⇒ page 65 .
Specified torque
Component
Specified torque
Bracket - T10014- in cylinder
block
20 Nm
– Raise engine slightly using workshop hoist - V.A.G 1202A- or
workshop hoist - VAS 6100- until adapter - 10-222A/3- and
adapter - 10-222A/16- are relieved.
50
Rep. gr.15 - Cylinder head, valve gear
Prote
cted
by
– Screw bracket - T10014- in threaded hole in cylinder block in
area of coolant pump.
AG.
Both lifting eyes for the support bracket are located on the cylinder
head. This is the reason why an additional bracket must be at‐
tached to the cylinder head to support the engine.
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– Remove toothed belt tensioning roller.
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– Removing, tensioning toothed belt, (for vehicles 01.06 ►)
⇒ page 73 .
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Unbolt support bracket - 10 - 222 A- with adapter - 10 - 222
A /3- and adapter - 10 - 222 A /16- from adapter - 10 - 222 A /
23- and lay to one side
Vehicles 01.06 ►
– Remove securing bolt for toothed belt tensioner.
Continuation for all vehicles
– Install hub and camshaft pulley ⇒ page 87 .
– Unscrew rear toothed belt guard securing bolts -2- and -4-.
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– Remove intake manifold ⇒ page 155 .
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– Unscrew Hall sender - G40- -3-.
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51
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove cylinder head bolts. Note sequence for this (see fig‐
ure).
– Lift the cylinder head slightly and remove it from the cylinder
block past the side of the toothed belt guard. (Engines 01.06
► toothed belt tensioner remains in engine support).
Note
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The cylinder head must be guided carefully
to prevent damage.
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♦ Always renew cylinder head bolts.
♦ In cases of repair carefully remove gasket remains from cyl‐
inder head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces. When using abrasive
paper do not use a grade less than 100.
♦ Carefully remove remains of emery and abrasives.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ Handle gasket very carefully. Damage to the silicone coating
or the indented area will lead to leaks.
♦ Engines 01.06 ► cylinder head must be fitted so that tensioning
– Turn crankshaft to TDC marking before fitting cylinder head.
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– Turn crankshaft against engine direction of rotation until all
pistons are about the same distance below TDC.
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– Position cylinder head gasket.
– Fit cylinder head and hand-tighten all cylinder head bolts.
– Tighten cylinder head in 4 stages in sequence shown as fol‐
lows:
1-
Tighten initially with torque wrench:
Stage I = 35 Nm
Stage II = 60 Nm
2-
Turn further with rigid spanner:
Stage III = 1/4 turn (90°)
Stage IV = 1/4 turn (90°)
Note
After repair work it is not necessary to retighten the cylinder head
bolts.
– Install hub for camshaft pulley ⇒ page 87 .
52
Rep. gr.15 - Cylinder head, valve gear
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roller stud is guided into tensioning roller. To do this, a second
person is necessary.
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Installation is carried outs in the reverse order; note the following:
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– When installing camshaft pulley, turn No. 1 cylinder cams
-arrows- so that they point evenly upwards. Turn crankshaft,
in engine direction of rotation, to TDC marking before fitting
toothed belt.
– Bolt intake manifold with new gasket to cylinder head
⇒ page 155 .
– Installing, tensioning toothed belt (for vehicles ► 12.05)
⇒ page 65 .
– Installing, tensioning toothed belt (for vehicles 01.06 ►)
⇒ page 73 .
Vehicles ► 12.05
– Install support bracket - 10 - 222 A- again and unbolt retainer
- T10014- .
Continuation for all vehicles
– Install poly V-belt ⇒ page 17 and
⇒ Item 6 (page 15) .
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– Notes on installing oil supply line ⇒ page 103 .
– Install particulate filter (only engine codes BRR and BRS)
⇒ page 163 .
rrectness of i
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spec
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wit
– Install front exhaust pipe ⇒ page 158 .
– Install turbocharger support and oil return for turbocharger.
– Reconnect all connecting, coolant, vacuum and intake hoses
to cylinder head.
– Reconnect all other respective electrical wiring to cylinder
head.
– Replenish coolant ⇒ page 108 .
– Install charge air cooler/turbocharger and air filter/turbocharg‐
er connecting pipes.
– Install any noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
AG.
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
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Specified torques
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– Carry out road test and read event memory afterwards ⇒ Ve‐
hicle diagnostic tester.
♦ ⇒ “1.1 Assembly overview - silencers/catalytic converters”,
page 158
♦ ⇒ “1.2 Assembly overview - silencers/particulate filter”,
page 159
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
1.3
Removing and installing cylinder head
cover
Special tools and workshop equipment required
1. Cylinder head
53
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Torque wrench - V.A.G 1331-
♦ Sealant ⇒ Electronic Parts Catalogue (ETKA)
Note
Renew cylinder head cover gasket and seal for bolts if damaged.
Removing
– Remove upper toothed belt guard.
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– Remove intake manifold flap motor - V157⇒ Item 2 (page 155) .
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Continuation for all engine codes
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– Pull oil dipstick out.
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– Remove exhaust gas recirculation connecting pipe
⇒ Item 3 (page 168) .
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Engine codes BRR and BRS
– Pull off breather hose for crankcase breather.
– Unbolt cylinder head cover.
Installing
Installation is carried out in the reverse order; note the following:
– Apply a drop of sealant ⇒ Electronic Parts Catalogue (ETKA)
(∅ approx. 5 mm) on edges of both sealing surfaces of bearing
cap and cylinder head at front of engine -arrows-.
54
Rep. gr.15 - Cylinder head, valve gear
rrectness of i
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nf
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spec
atio
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Apply a drop of sealant ⇒ Electronic Parts Catalogue (ETKA)
(∅ approx. 5 mm) on edges of both sealing surfaces of bearing
cap and cylinder head at rear of engine -arrows-.
– Tighten cylinder head cover securing bolts hand tight in se‐
quence as shown.
– Tighten all bolts in sequence as shown.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
♦ ⇒ “4.1 Assembly overview - intake manifold, engine codes
BRR and BRS”, page 155
rrectness of i
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1. Cylinder head
55
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.4
Checking compression
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spec
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Special tools and workshop equipment required
♦ Jointed wrench 10 mm - 3220♦ Torque wrench - V.A.G 1331♦ Adapter - V.A.G 1381/12Test prerequisite
Engine oil temperature min. 30 °C.
AG.
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– Detach central connector for unit injectors.
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Test procedure
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•
– Remove all glow plugs using 10 mm jointed wrench - 3220- .
56
Rep. gr.15 - Cylinder head, valve gear
do
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♦ Compression tester - V.A.G 1763-
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Screw in adapter - V.A.G 1381/12- in place of the glow plugs.
– Check compression using compression tester - V.A.G 1763- .
Note
Using the compression tester ⇒ Operating instructions
– Operate starter until tester shows no further pressure in‐
crease.
Compression pressures:
New: 25…31 bar
Wear limit: 19 bar.
Maximum permissible difference between all cylinders: 5 bar
– Install all glow plugs using 10 mm jointed wrench - 3220- .
– Read event memory ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
1.5
Removing and installing vacuum pump
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The vacuum pump may, under no circumstances, be disman‐
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57
AG.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Special tools and workshop
equipment required
♦ Torque wrench - V.A.G
1331♦ Hand vacuum pump - VAS
6213♦ Water drainage container V.A.G 1390/1♦ Spring-type clip pliers VAS 5024 A-
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Wear protective gloves.
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The fuel and the fuel lines in the fuel system can become very
hot (danger of scalding)!
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Vehicles with fuel preheating
– Pull supply hose -1- (white marking) and return hose -2- (blue
marking) off fuel filter.
– Connect hand vacuum pump - VAS 6213- with water drainage
container - V.A.G 1390/1- to return hose -2-.
– Operate hand vacuum pump - VAS 6213- until no more fuel
comes out of return hose. Be careful that no fuel is sucked into
hand vacuum pump.
Vehicles without fuel preheating
– Pull supply hose off fuel filter.
– Separate return hose connection (blue marking)/return line
(brown) next to fuel filter.
– Connect hand vacuum pump - VAS 6213- with water drainage
container - V.A.G 1390/1- to return hose.
– Operate hand vacuum pump - VAS 6213- until no more fuel
comes out of return hose. Be careful that no fuel is sucked into
hand vacuum pump.
Continuation for all vehicles
– Remove coolant expansion tank and place to one side (leaving
hoses connected).
– Remove charge air pipe between intake manifold and charge
air cooler.
– Detach brake servo vacuum line -1- from vacuum pump -4-.
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– Detach fuel supply line -2- from vacuum pump -4-.
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Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Ensure that vacuum pump coupling seats properly in shaft.
♦ Always renew vacuum pump seals.
– Install vacuum pump and tighten upper securing bolts.
– Tighten lower securing bolts .
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Connect return hose (blue or with blue marking) -3- and vac‐
uum line -1- to vacuum pump.
– Connect supply hose (black) to supply connection -2- and
brake servo vacuum line -1- to vacuum pump -4-.
Vehicles with fuel preheating
– Connect supply hose ⇒ Item 3 (page 129) and return hose
⇒ Item 2 (page 129) to fuel filter. agen AG. Volkswagen AG do
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– Pull supply hose ⇒ aItem
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Continuation for all vehicles
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– Install charge air pipe between intake manifold and charge air
cooler.
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– Connect return hose to return line.
– Secure coolant expansion tank.
Note
The vacuum pump must always be checked for internal leaks be‐
tween fuel side and oil side after reinstalling a used vacuum pump
⇒ page 62 .
– Bleed fuel system ⇒ Maintenance ; Booklet 19.1 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
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Checking delivery pressure of vacuum
pump
60
Rep. gr.15 - Cylinder head, valve gear
AG.
♦ Torque wrench - V.A.G 1331-
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– Carry out road test and read event memory ⇒ Vehicle diag‐
nostic tester.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Tandem pump tester - VAS 5187- with adapter - VAS 5187/7-
Special tools and workshop equipment required
♦ Vehicle diagnosis tester
Test prerequisites
•
Coolant temperature must be at least 85 °C.
•
Unit injectors OK.
•
Fuel filter and fuel lines must not be blocked.
Procedure
WARNING
The fuel and the fuel lines in the fuel system can become very
hot (danger of scalding)!
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– Unscrew plugss -arrow-.
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61
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
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– Connect ⇒ Vehicle diagnostic tester.
– Select Read measured value block in Engine electronics .
– Read off idling speed in ⇒ Vehicle diagnostic tester.
– Increase speed to 4000 rpm.
– Check displayed pressure on pressure gauge.
Specification: at least 7.5 bar
If the specification is not attained:
– Using a hose clamp, clamp off return line between fuel filter
and vacuum pump.
– Increase speed to 4000 rpm.
– Renew O-rings for unit injectors ⇒ page 144 .
– Renew vacuum pump ⇒ page 57 .
Note
After removing pressure gauge, tighten sealing. Renew seal al‐
ways.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
1.7
Checking for internal leaks
Note
The vacuum pump must be checked for internal leaks between
fuel side and oil side after reinstalling a used vacuum pump, e.g.
after renewing or repairing a cylinder head and/or when installing
a "short" engine. In the event of a leak, it is possible for the fuel
to mix with the oil which may cause engine damage.
Special tools and workshop equipment required
62
Rep. gr.15 - Cylinder head, valve gear
AG.
If the specification is not attained:
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If specification is now obtained:
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Specification: at least 7.5 bar
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– Check displayed pressure on pressure gauge.
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– Start engine and run at idling speed.
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– Connect tandem pump tester - VAS 51875187/7- as shown.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Charge air system tester - V.A.G 1687-
Procedure
– Pull fuel supply hose (white marking) and fuel return hose
(blue marking) off vacuum pump.
– Seal fuel return connection on vacuum pump with a plug. Se‐
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Prepare charge air system tester
ed
is
or
Note
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
– Connect compressed air hose -1- (compressed air supply) to
charge air system tester - V.A.G 1687- .
Note
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– Open valve -3-.
– Adjust pressure to 1.0 bar with pressure control valve -2-.
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– Connect test connection -5- to fuel supply connection of vac‐
uum pump using commercially available compressed air con‐
nection and a section of fuel hose. Secure by means of springtype clip.
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– Unscrew pressure control
valve -2- completely and
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valves -3- and -4-. ss
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Caution
The maximum test pressure is 1.3 bar and this must not be
exceeded.
– Open valve -4- and wait until test circuit is full. If necessary,
regulate pressure to 1.0 bar.
– Close valve -3- to maintain pressure and observe pressure
drop over a period of 1 minute.
If the pressure does not drop the vacuum pump can be reused, if
the pressure drops the vacuum pump must be renewed.
1. Cylinder head
63
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
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toothed belt
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Toothed belt drive
⇒ “2.1 Assembly overview -
⇒ “2.3 Removing and installing toothed belt, vehicles 01.06 ►”,
page 73
2.1
Assembly overview - toothed belt drive
6 - Bolt
❑ 25 Nm
7 - Camshaft pulley
8 - Hub
❑ With sender wheel
❑ Use counterhold tool T10051- to loosen and
tighten.
❑ To remove, use puller T10052- .
❑ Removing and installing
⇒ page 87 .
9 - Bolt
❑ Renew after removing.
❑ 10 Nm
10 - Rear toothed belt guard
11 - Sealing grommet
❑ Renew if damaged.
12 - Idler roller
13 - Coolant pump
❑ Removing and installing ⇒ page 114 .
64
Rep. gr.15 - Cylinder head, valve gear
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5 - Bolt
❑ 100 Nm
AG.
4 - Tensioning roller
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3 - Nut
❑ 20 Nm +45°
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2 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
❑ Removing, installing
and tensioning toothed
belt (for vehicles ►
12.05) ⇒ page 65 .
❑ Removing, installing
and tensioning toothed
belt (for vehicles 01.06
►) ⇒ page 73 .
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1 - Toothed belt guard upper
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⇒ “2.2 Removing and installing toothed belt, vehicles ► 12.05”,
page 65
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
14 - Crankshaft toothed belt pulley
15 - Bolt
❑ Renew after removing.
❑ Do not additionally oil or grease thread and shoulder.
❑ Turning further can be done in several stages.
❑ Use counterhold for toothed belt pulley - 3099- to loosen and tighten
❑ 120 Nm + 90°
16 - Bolt
❑ 15 Nm
17 - Nut
❑ 20 Nm
18 - Toothed belt guard lower part
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19 - Belt pulley and vibration
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❑ Can only be installed
in one position. Holes are offset.
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20 - Bolt
21 - Cover
❑ Renew if damaged.
22 - Toothed belt guard centre part
23 - Engine mounting
24 - Bolt
❑ Renew after removing.
❑ 40 Nm +180°
25 - Bolt
❑ Securing point for charge air cooler connecting pipe.
❑ 10 Nm
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Removing and installing toothed belt,
vehicles ► 12.05
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❑ 10 Nm + 90°
From 01.06 a modified engine support has been introduced, it is
no longer necessary to remove the engine support and support
the engine for the procedure "Removing, installing and tensioning
toothed belt".
AG.
-1-: Engine support ► 12.05 (removal necessary) ⇒ page 14
2. Toothed belt drive
65
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
-2-: Engine support 01.06 ► (removal not necessary).
Removing
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66
Rep. gr.15 - Cylinder head, valve gear
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♦ Torque wrench - V.A.G
1332-
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♦ Torque wrench - V.A.G
1331-
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♦ Crankshaft stop - T10050-
AG.
♦ Locking pin - T10115-
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Special tools and workshop
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♦ Counterhold tool - T10172-
♦ Special wrench, long reach - T10264-
AG.
– Unbolt right cover and battery cover from lock carrier ⇒ Rep.
gr. 63 .
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– Remove bulkhead on left and right ⇒ General body repairs,
exterior; Rep. gr. 50 ; Plenum chamber bulkhead .
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Removing
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♦ Support bracket - 10 - 222 A- with adapter - 10 - 222 A /23and adapter - 10 - 222 A /16-
rrectne
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Prote
cted
by
– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
– Remove charge air pipe -1- between charge air cooler and
turbocharger.
– Carefully cover or seal open ends.
2. Toothed belt drive
67
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove connecting hose -1- from air filter and crankcase
breather hose -2-.
– Remove poly V-belt ⇒ page 17 .
– Remove pin from poly V-belt tensioning element.
– Remove tensioning element ⇒ Item 6 (page 15) .
– Remove upper toothed belt guard.
– Remove vibration damper/belt pulley ⇒ Item 4 (page 15) .
– Unclip cover caps on suspension strut turret.
– Fit adapter - 10 - 222 A /23- -1- on foremost suspension strut
turret and on lock carrier -arrows-.
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– Bolt support bracket - 10 - 222 A- to respective adapter 10-222A/23– Support engine on lifting eyes on cylinder head, using adapter
- 10 - 222 A /23- and adapter - 10 - 222 A /16-
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
68
Rep. gr.15 - Cylinder head, valve gear
AG.
supported with support bracket - 10 - 222 A- !
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♦ The assembly mounting may only be removed if the engine is
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– Remove securing bolts from assembly mounting to engine
bracket, assembly mounting to body -arrows- and completely
remove assembly mounting.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Unbolt engine bracket from cylinder block -arrows- and re‐
move.
Note
♦ When loosening both upper engine bracket bolts the engine
must be raised slightly with the support bracket.
♦ When loosening the lower engine bracket bolt the engine must
be lowered slightly with the support bracket.
– Remove centre and lower toothed belt guards.
– Set engine to TDC No. 1 cylinder.
Note
Turn crankshaft until marking on crankshaft toothed belt pulley
and tooth segment of camshaft pulley is on top. The arrow on the
rear toothed belt guard must align with the markings on the cam‐
shaft sender wheel -arrows-.
– Lock hub with diesel injection pump locking pin - 3359- . To do
this, insert locking pin - 3359- through free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley in position with crankshaft
stop - T10050- . To do this, push crankshaft stop - T10050into teeth of toothed belt pulley from latter's face side.
Note
The markings on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. At the same time, the pin of the crankshaft
stop - T10050- must engage in the drilling in the sealing flange.
olkswagen AG
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pulley can be moved within elongated holes.
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Loosen securing bolts -1- of camshaftsspulley until camshaft
2. Toothed belt drive
69
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
From 01.06 ►, a new toothed belt tensioner is installed. The ten‐
sioner has an additional hexagon hole -arrow-. Use angle driver
- T10264- instead of 2-hole pin wrench - T10020- to loosen and
tension the toothed belt. This does not alter the procedure.
– Turn 2-hole pin wrench - T10020- anti-clockwise until toothed
belt tensioning roller can be locked using locking pin T10115- .
– Turn 2-hole pin wrench - T10020- clockwise as far as stop and
hand-tighten securing nut -1-.
– Remove toothed belt first from coolant pump and then from
remaining toothed pulleys.
Installing
•
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cured to right stop.
Note
Adjustment work on toothed belts must be performed only on cold
engines, as the indicator position on the tensioning element varies
depending on the engine temperature.
– Turn camshaft pulley in its elongated holes to centre position
-arrows-.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller, camshaft pulley and idler roller.
AG.
Rep. gr.15 - Cylinder head, valve gear
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– Finally, fit toothed belt on coolant pump toothed belt pulley.
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Camshaft locked with lockingy Vpin
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
Ensure that belt tensioner seats correctly in rear toothed belt
guard -arrow-.
– Undo securing nuts of tensioning roller and pull out locking pin
- T10115- .
Note
From 01.06 ►, a new toothed belt tensioner is installed. The ten‐
sioner has an additional hexagon hole -arrow-. Use angle driver
- T10264- instead of 2-hole pin wrench - T10020- to loosen and
tension the toothed belt. This does not alter the procedure.
– Now carefully turn tensioning roller clockwise using 2-hole pin
wrench - T10020- until indicator is in middle of gap in base
plate -arrow-.
Ensure that securing nut does not turn as well.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.
rrectness of i
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in t
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– In this position, tighten camshaft pulley securing bolts -1-.
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft two revolutions in direction of engine rotation
until crankshaft is just before TDC for No. 1 cylinder.
do
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– Fit counterhold - T10172- with pin - T10172/4- as shown.
Press counter-hold tool - T10172- in direction of arrow and
keep camshaft sprocket in pretensioning position.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition
04.2013
AG. Volkswagen
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– Turn crankshaft slightly against direction of engine rotation
until pin of crankshaft stop - T10050- is positioned just before
hole in sealing flange -arrow-.
– Now turn crankshaft in direction of engine rotation until pin of
crankshaft stop - T10050- engages in sealing flange whilst
turning.
– Fit counterhold - T10172- with pin - T10172/4- as shown.
Press counter-hold tool - T10172- in direction of arrow and
keep camshaft pulley in pretensioning position.
– In this position, tighten camshaft pulley securing bolts -1-.
– Remove locking pin - 3359- and crankshaft stop - T10050- .
– Turn crankshaft two revolutions in direction of engine rotation
until crankshaft is just before TDC for No. 1 cylinder.
– Repeat measurement.
– Install lower toothed belt guard and vibration damper/belt pul‐
ley ⇒ Item 4 (page 15) .
– Install middle toothed belt guard.
72
Rep. gr.15 - Cylinder head, valve gear
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– Loosen securing bolts -1- of camshaft pulley.
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Check whether crankshaft
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ss
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Using new securing bolts -arrows-, mount engine bracket on
cylinder block and tighten securing bolts.
Note
Before installing assembly mounting, tighten all engine bracket
bolts to specified torque.
–
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⇒ page 14 .
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– Install tensioning element ⇒ Item 6 (page 15) .
– Install upper toothed belt guard.
– Install charge air cooler/turbocharger and air filter/turbocharg‐
er connecting pipes.
– Install any noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Install bulkhead on left and right ⇒ General body repairs, ex‐
terior; Rep. gr. 50 ; Plenum chamber bulkhead .
– Install right cover and battery cover on lock carrier.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
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– Install poly V-belt ⇒ page 17 .
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– Fit engine assembly mounting to engine bracket by bringing
contact surfaces together using support bracket - 10 - 222 Aand tighten ⇒ page 14 .
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♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 15
♦ ⇒ “2.1 Assembly overview - charge air system”, page 139
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gr. 50 ; Assembly overview - noise insulation
AG.
2.3
Removing and installing toothed belt,
vehicles 01.06 ►
Note
From 01.06 a modified engine support has been introduced, it is
no longer necessary to remove the engine support and support
the engine for the procedure "Removing, installing and tensioning
toothed belt".
-1-: Engine support ► 12.05 (removal necessary) ⇒ page 14
2. Toothed belt drive
73
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
-2-: Engine support 01.06 ► (removal not necessary).
Special tools and workshop
equipment required
♦ Diesel injection pump lock‐
ing pin - 3359♦ Locking pin - T10060 A♦ Crankshaft stop - T10100(for oval crankshaft toothed
belt pulley)
♦ Counterhold tool - T10172♦ Special wrench, long reach
- T10264-
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Rep. gr.15 - Cylinder head, valve gear
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♦ Locking tool - T10265-
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Crankshaft stop - T10050- (for round crankshaft toothed belt
pulley)
Removing
– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Noise insulation .
– Remove charge air pipe -1- between charge air cooler and
turbocharger.
– Carefully cover or seal open ends.
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– Remove connecting hose -1breather hose -2-.
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u filter and crankcase
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– Remove poly V-belt ⇒ page 17 .
– Remove poly V-belt tensioning element.
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t to the co
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spec
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n in
wit
– Remove upper toothed belt guard.
– Remove vibration damper/belt pulley ⇒ Item 4 (page 15) .
– Remove lower and centre toothed belt guards
Note
Gradual introduction of oval crankshaft toothed belt pulleys.
When installing this toothed belt pulley, the crankshaft stop T10100- must be installed to determine the TDC position.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Characteristics of crankshaft toothed belt pulley:
A = Round toothed belt pulley, lock using crankshaft stop T10050- , TDC marking at 12 o'clock
B = Oval toothed belt pulley, lock using crankshaft stop - T10100- ,
TDC marking at 1 o'clock
Vehicles with round crankshaft toothed belt pulley:
– Set engine to TDC No. 1 cylinder.
Note
Turn crankshaft until marking on crankshaft toothed belt pulley
and tooth segment of camshaft pulley is on top. The arrow on the
rear toothed belt guard must align with the markings on the cam‐
shaft sender wheel -arrows-.
– Lock hub with diesel injection pump locking pin - 3359- . To do
this, insert locking pin - 3359- through free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley in position with crankshaft
stop - T10050- . To do this, push crankshaft stopag-eT10050n AG. Volkswagen AG do
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The marks on the crankshaft pulley and the crankshaft stop T10050- must be aligned. At the same time, the pin of the crank‐
shaft stop - T10050- must engage in the drilling in the sealing
flange.
Vehicles with oval crankshaft toothed belt pulley:
– Set engine to TDC No. 1 cylinder.
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Rep. gr.15 - Cylinder head, valve gear
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76
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
Turn crankshaft until marking on crankshaft toothed belt pulley
and tooth segment of camshaft pulley is on top. The marking on
the rear toothed belt guard must align with the marking on the
camshaft sender wheel -arrow-.
– Lock hub with diesel injection pump locking pin - 3359- . To do
this, insert locking pin - 3359- through free elongated hole on
left into hole in cylinder head.
– Lock crankshaft toothed belt pulley in position with crankshaft
stop - T10100- . To do this, push the crankshaft stop into the
teeth of the toothed belt pulley from the latter's face side..
Note
The marks on the crankshaft toothed belt pulley and the crank‐
shaft stop must align. When doing this, the pin of the crankshaft
stop must engage in the drilling of sealing flange.
Continuation for all vehicles
– Mark direction of rotation of toothed belt.
– Loosen securing bolts -1- of camshaft pulley until camshaft
pulley can be moved within elongated holes.
– Loosen tensioning roller securing nut -1-.
rrectness of i
t to the co
nf
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m
spec
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n in
wit
– Turn eccentric of tensioning roller anti-clockwise -arrow- using
socket - T10264- , until the tensioning roller can be locked with
locking tool - T10265- .
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Turn belt tensioner eccentric clockwise -arrow- to stop. Handtighten securing bolt -1-.
– Remove toothed belt first from coolant pump and then from
remaining toothed belt pulleys.
Installing
Installation is carried out in the reverse order; note the following:
•
Camshaft locked with locking pin - 3359- .
•
Crankshaft locked with crankshaft stop - T10050- or crank‐
shaft stop - T10100- .
•
Tensioning roller locked with locking pin - T10265- and se‐
cured to right stop with securing nut.
Note
Adjustment work on toothed belts must be performed only on cold
engines, as the indicator position on the tensioning element varies
depending on the engine temperature.
– Turn camshaft pulley in its elongated holes to centre position
-arrows-.
– Guide toothed belt through gap between engine support and
engine.
– Fit toothed belt to crankshaft toothed belt pulley, tensioning
roller, camshaft pulley and idler roller.
– Finally, fit toothed belt on coolant pump toothed belt pulley.
Ensure that belt tensioner seats correctly in rear toothed belt
guard -arrow-.
– Loosen tensioning roller securing nut -1-.
– Carefully turn eccentric of tensioning roller clockwise -arrowusing angled screwdriver - T10264- until indicator -2- is in the
middle of gap in base plate.
Note
Ensure that securing nut does not turn as well.
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– Hold tensioning roller in this position and tighten nut of ten‐
sioning roller.
AG.
Rep. gr.15 - Cylinder head, valve gear
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rrectness of i
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– Pull out the locking pin - T10265- from the tension roller.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Fit counterhold - T10172- with pin - T10172/4- as shown in
illustration, and keep the toothed belt under tension on pulling
side, by pressing in -direction of arrow-.
– Tighten bolts -1- of camshaft pulley.
– Remove locking pin - 3359- .
Vehicles with round crankshaft toothed belt pulley:
– Remove crankshaft stop - T10050- .
– Turn crankshaft two revolutions in direction of engine rotation
until crankshaft is just before TDC for No. 1 cylinder.
– Lock hub with locking pin - 3359- whilst turning engine in di‐
rection of rotation.
– Check whether crankshaft can be locked with crankshaft stop
- T10050- .
If crankshaft cannot be locked:
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– Loosen securing bolts -1- of camshaft
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wit
– Turn crankshaft slightly against direction of engine rotation
until pin of crankshaft stop - T10050- is positioned just before
hole in sealing flange -arrow-.
– Turn crankshaft in direction of engine rotation until crankshaft
stop - T10050- pin engages in sealing flange whilst turning.
Vehicles with oval crankshaft toothed belt pulley:
– Remove crankshaft stop - T10100- .
– Turn crankshaft 2 rotations in direction of engine rotation until
crankshaft is just before TDC again.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
AG. Volkswagen
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– Check whether crankshaft can be locked with crankshaft stop
- T10100- .
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– Loosen securing bolts -1- of camshaft pulley.
– Turn crankshaft slightly against direction of engine rotation
until pin of crankshaft stop - T10100- is positioned just before
hole in sealing flange -arrow-.
– Turn crankshaft in engine direction of rotation until crankshaft
stop - T10100- pin arrow engages in sealing flange whilst turn‐
ing.
Continuation for all vehicles
80
Rep. gr.15 - Cylinder head, valve gear
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If crankshaft cannot be locked:
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Fit counterhold - T10172- with pin - T10172/4- as shown.
Press counter-hold tool - T10172- in direction of arrow and
keep camshaft pulley in pretensioning position.
– In this position, tighten camshaft pulley securing bolts -1-.
– Remove locking pin - 3359- and crankshaft stop - T10050- or
crankshaft stop - T10100- .
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– Turn crankshaft two revolutions
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is
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– Check and, if necessary,
repeat adjustment.
au
– Install vibration damper/belt pulley.
– Install tensioning element ⇒ Item 6 (page 15) .
– Install poly V-belt ⇒ page 17 .
– Install charge air cooler/turbocharger and air filter/turbocharg‐
er connecting pipes.
– Install any noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 15
♦ ⇒ “2.1 Assembly overview - charge air system”, page 139
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
rrectness of i
t to the co
nform
spec
at
i
h re
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in t
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– Install upper toothed belt guard.
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– Remove middle and lower toothed belt guards.
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81
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 82
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⇒ “3.2 Measuring axial clearance of camshaft”, page 83
⇒ “3.4 Removing and installing
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⇒ “3.5 Removing and installing valve stem seal”, page 92
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4 - Washer
❑ For cylinder head bolts.
❑ Insert in cylinder head
before installing bearing
caps
5 - Bucket tappet
❑ Do not interchange.
❑ With hydraulic valve
clearance compensa‐
tion.
❑ Set down with contact
surface facing down‐
wards.
❑ Oil contact surface.
❑ Before removing, remove camshaft bearing caps
❑ Before installing, check camshaft axial clearance ⇒ page 83 .
6 - Cotters
7 - Valve spring plate
8 - Outer valve spring
❑ Removing and installing:
❑ Cylinder head removed, with valve spring compressor - 2037- installed: ⇒ page 92
82
Rep. gr.15 - Cylinder head, valve gear
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3 - Cylinder head bolt
❑ Renew after removing.
❑ Before installing, insert
washers
⇒ Item 4 (page 82) in
cylinder head.
❑ Observe sequence
when loosening and
tightening ⇒ page 47 .
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2 - Rocker arm shaft
❑ Do not interchange.
❑ Removing and installing
⇒ page 87 .
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1 - Bolt
❑ Renew after removing.
❑ Observe sequence
when loosening and
tightening ⇒ page 87 .
❑ 20 Nm + 90°
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⇒ “3.3 Removing and installing
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
9 - Inner valve spring
❑ Removing and installing:
❑ Cylinder head removed, with valve spring compressor - 2037- installed: ⇒ page 92
10 - Valve stem seal
❑ Renew. ⇒ page 92 .
11 - Valve guide
❑ Checking ⇒ page 94 .
12 - Unit injector
❑ Removing and installing ⇒ page 146 .
13 - Cylinder head
❑ See note ⇒ page 82 .
14 - Seal
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove residual oil from camshaft journal using a clean cloth.
❑ To install, tape over groove in taper of camshaft (e.g. using Sellotape).
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❑ Removing and installing ⇒ page
85
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15 - Valves
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❑ Valve dimensions ⇒aupage 84
ss
17 - Camshaft
❑ Checking radial clearance with Plastigage; wear limit: 0.11 mm.
❑ Runout: max. 0.01 mm.
❑ Checking axial clearance ⇒ page 83 .
❑ Removing and installing ⇒ page 87 .
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16 - Bearing shell
❑ Do not interchange used bearing shells (mark).
❑ Ensure that retaining lugs are correctly seated in bearing caps and cylinder head
18 - Bearing cap
❑ Installation sequence ⇒ page 87 .
❑ Seal bearing caps 1 and 5 with sealant as per ⇒ Electronic Parts Catalogue (ETKA) ⇒ page 84 .
Measuring axial clearance of camshaft
Prote
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by
♦ Dial gauge
AG.
♦ Universal dial gauge bracket - VW 387-
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19 - Bolt
❑ Renew after removing.
❑ 8 Nm + 90°
Checking camshaft axial clearance
Test procedure
– Check with bucket tappets removed and with first, third and
last bearing caps fitted.
Wear limit: max. 0.15 mm
3. Valve gear
83
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Seal parting surfaces of bearing caps 1 and 5 with sealant
– Apply sealant ⇒ Electronic Parts Catalogue (ETKA) thinly and
evenly on surfaces -1-.
Note
Be careful and ensure that no sealant gets into grooves
-arrows-.
Valve dimensions
Note
Valves must not be reworked. Only lapping-in is permitted.
Dimension
∅a
∅b
c
α
mm
mm
mm
∠°
Inlet valve
Exhaust valve
35.95
6.980
89.95
45
31.45
6.956
89.95
45
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Rep. gr.15 - Cylinder head, valve gear
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3.3
Removing and installing camshaft oil seal
Special tools and workshop
equipment required
♦ Fitting tool - 10 - 203♦ Oil seal extractor - 3240♦ Torque wrench - V.A.G
1331♦ Torque wrench - V.A.G
1332♦ Bolt M12 x 1.5 x 65
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♦ The toothed belt need not be removed completely.
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♦ Once the crankshaft is locked it need only be removed from
the camshaft pulley.
3. Valve gear
85
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove camshaft sprocket and hub ⇒ page 87 .
– Unscrew inner part of oil seal extractor - 3240- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐
tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
Installing
Installation is carried out in the reverse order; note the following:
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
– Tape over groove in taper of camshaft (e.g. using Sellotape).
– Carefully place seal onto camshaft.
– Press in oil seal with press piece of fitting tool - 10 - 203- and
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⇒ page 65 .
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Specified torques
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– Installing, tensioning toothed belt (for vehicles 01.06
►)
ss
⇒ page 73 .
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♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
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Rep. gr.15 - Cylinder head, valve gear
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86
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3.4
Removing and installing camshaft
Special tools and workshop
equipment required
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T10052e
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♦ Sealant ⇒ Electronic Parts
Catalogue (ETKA)
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Removing
Note
♦ The toothed belt need not be removed completely.
♦ Once the crankshaft is locked it need only be removed from
the camshaft pulley.
– Loosening toothed belt, (for vehicles ► 12.05) ⇒ page 65 .
– Loosening toothed belt, (for vehicles 01.06 ►) ⇒ page 73 .
– Remove locking pin - 3359- .
3. Valve gear
87
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove securing bolts -1- for camshaft pulley.
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– Loosen hub securing bolt -1-.
– Use counterhold tool - T10051- to do this.
Note
Turn hub clockwise if the counterhold cannot be fitted.
– Unscrew hub securing bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.
AG.
Prote
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Hold puller with 30 mm spanner whilst doing this.
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Note
– Remove hub from taper of camshaft.
– Remove cylinder head cover ⇒ page 53 .
– Mark rocker arm shafts using a permanent felt tip marker to
prevent interchanging -arrows-.
88
Rep. gr.15 - Cylinder head, valve gear
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– Apply tension to hub by tightening puller evenly until hub sep‐
arates from taper of camshaft.
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– Pull camshaft pulley off hub.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Loosen lock nuts of adjustment screws -1- and remove ad‐
justment screws.
– Loosen securing bolts -2- for rocker arm shaft working from
outside to inside using Socket XZN 10 - 3410- . Remove rocker
arm shaft.
– Remove vacuum pump ⇒ page 57 .
– First remove bearing caps 5, 1 and 3. Loosen bearing caps 2
and 4 alternately and diagonally.
– Remove camshaft.
Installing
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Installation is carried out in the reverse
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order; note
the
following:
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♦ When camshaft is installed, No. 1 cylinder cams must point
upwards.
♦ Do not interchange used bearing shells (mark).
♦ When installing the camshaft, ensure proper seating of retain‐
ing lugs in bearing caps and cylinder head.
♦ Before installing bearing caps, ensure that cylinder head bolt
– Oil running surfaces of bearing shells.
AG.
– Install bearing caps 5, 1 and 3 using new bolts.
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– Tighten bearing caps 2 and 4 using alternate and diagonal
sequence.
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– Install bearing caps 2 and 4 using new bolts.
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washers are inserted in the cylinder head.
Note
♦ Seal parting surfaces of bearing caps 1 and 5 with sealant as
per ⇒ Electronic Parts Catalogue (ETKA) .
♦ Bearing cap 5 must be flush with outer edge of cylinder head,
otherwise leaks can occur at the vacuum pump.
– Tighten bearing caps 5, 1, and 3 also.
– Install camshaft seal ⇒ page 85 .
– Fit hub on camshaft.
3. Valve gear
89
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Tighten securing bolt -1- of hub.
– Use counterhold - T10051- to do this.
– Push camshaft sprocket onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be
on top.
– Align camshaft pulley at centre of elongated holes.
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– Lock hub with diesel
ho injection pump locking pin - 3359- .
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– Installing, tensioning toothed belt (for vehicles 01.06 ►)
⇒ page 73 .
– Renew unit injector ball studs ⇒ Item 5 (page 143) .
Note
Each time the rocker arm shaft is removed and each time work is
performed which requires adjustment of the unit injector, the ad‐
justment screws ⇒ Item 4 (page 143) and the ball pins
⇒ Item 5 (page 143) of the unit injectors must be renewed.
– Fit rocker arm shafts with new adjustment screws and tighten
new securing bolts as follows:
AG.
Rep. gr.15 - Cylinder head, valve gear
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– First, tighten inner bolts -2-, and then outer bolts -1- evenly
and diagonally.
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– Installing, tensioning
toothed belt (for vehicles ► 12.05)
⇒ page 65 .
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d
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diesel
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Fit dial gauge onto adjustment screw
of
unit
injector
as
shown.
s
– Remove dial gauge.
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m
spec
atio
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wit
– 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 Bpositioned at lowest point.
– Now turn adjustment screw into rocker arm until significant re‐
sistance can be felt (unit injector is at limit stop).
– Slacken adjustment screw of stop by 180°.
– Hold adjuster bolt in this position and tighten lock nut.
– Install cylinder head cover ⇒ page 53 .
– Install vacuum pump ⇒ page 57 .
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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).
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– Install upper toothed belt guard.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
♦ ⇒ “1.1 Assembly overview - injectors”, page 143
3. Valve gear
91
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Removing and installing valve stem seal
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Removing
(With cylinder head installed)
Note
Cylinder heads with cracks between the valve seats may be used
without reducing engine life, provided the cracks are small and
not more than 0.5 mm wide.
– Remove camshaft ⇒ page 87 .
– 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).
92
Rep. gr.15 - Cylinder head, valve gear
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♦ Thrust piece for VW 541 / 1
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♦ Valve lever - VW 541/1 A-
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Special tools and workshop
equipment required
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Fit valve assembly tool - 2036- and adjust mountings to height
of studs.
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– Remove valve springs
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The valves are supported by the piston crown.
– Pull off valve stem seals using puller - 3047 A- .
Installing
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Note
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Installation is carried out in the reverse order; note the following:
– Place the plastic sleeve -A- supplied on the respective valve
stem. This will prevent the new valve stem seal -B- being
damaged.
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– Place new valve stem seal in fitting tool - 3129- .
AG.
– Oil valve stem seal sealing lip and press carefully onto the
valve guide.
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
♦ ⇒ “1.1 Assembly overview - injectors”, page 143
3. Valve gear
93
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
4
Inlet and exhaust valves
⇒ “4.1 Checking valve guides”, page 94
4.1
Checking valve guides
Special tools and workshop equipment required
♦ Universal dial gauge bracket - VW 387♦ Dial gauge
Test procedure
– 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.
– Determine rock. Wear limit: max. 1.3 mm
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Rep. gr.15 - Cylinder head, valve gear
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– Cylinder head must be renewed if rock exceeds wear limit.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
17 –
Lubrication
1
Sump, oil pump
⇒ “1.1 Assembly overview - sump and oil pump”, page 95
⇒ “1.2 Removing and installing oil sump”, page 96
⇒ “1.3 Engine oil”, page 99
1.1
Assembly overview - sump and oil pump
1 - Bolt
❑ 15 Nm
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2 - Nut
❑ 25 Nm
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3 - Bracket
❑ Attached to cylinder
block
4 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 99 .
5 - Guide tube
❑ with funnel
❑ Secured to oil filter
bracket.
6 - Bolt
❑ 10 Nm
7 - Dowel sleeves
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10 - Suction line
❑ Clean strainer if soiled.
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9 - Bolt
❑ 15 Nm
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8 - O-ring
❑ Renew after removing.
11 - Baffle plate
12 - Bolt
❑ 15 Nm
13 - Bolt
❑ 15 Nm
14 - Oil sump
❑ Clean sealing surface before fitting.
❑ Seal with Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
❑ Removing and installing ⇒ page 96 .
15 - Seal
❑ Renew after removing.
16 - Oil drain plug
❑ Renew plug with attached seal.
1. Sump, oil pump
95
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑ 30 Nm
17 - Bolt
❑ 10 Nm
18 - Oil level and oil temperature sender - G266❑ Not installed on all engines.
19 - Seal
❑ Renew after removing.
20 - Oil pump
❑ With 12 bar pressure relief valve.
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
21 - Chain sprocket for oil pump
22 - Bolt
❑ 25 Nm
23 - Bolt
❑ 15 Nm
un
le
26 - Chain tensioner with tensioning plate
❑ When installing, pretension spring and fit.
❑ 15 Nm
27 - Oil spray jet
❑ For piston cooling.
28 - Bolt
❑ Insert without sealant.
❑ 25 Nm
1.2
Removing and installing oil sump
AG.
Rep. gr.17 - Lubrication
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96
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Special tools and workshop equipment required
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25 - Chain
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24 - Sealing flange
❑ With seal.
❑ Must seat on dowel sleeves.
❑ Do not additionally oil or grease the oil seal sealing lip.
lkswagenusing
❑ Before installing, remove oil residue from crankshaft
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❑ Insert with silicone sealant ⇒ Electronic
Parts
Catalogue
(ETKA)
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ris pulley end ⇒ page 20
❑ Renewing crankshaft oil seal - belt
ho
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❑ Removing and installing ⇒ page
22 .
ss
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Torque wrench - V.A.G 1331-
♦ Allen key, long reach 5 mm - T10058-
rrectness of i
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♦ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
♦ Flat scraper
♦ Hand drill with plastic brush attachment
♦ Eye protection
Removing
– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
AG.
– Detach connector from oil level and oil temperature sender G266- , if fitted. Unclip line from sump.
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Observe environmental regulations for disposal.
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Note
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– Drain off engine oil.
– Unbolt sump using special wrench, long reach - T10058- .
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant residues from cylinder block with a flat scra‐
per .
1. Sump, oil pump
97
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
olkswagen AG
en AG. V
does
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– Remove sealant residues on sump
ksw with rotating brush, e.g.
not
Vol
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hand drill with plastic brush
binsert (wear safety goggles).
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tho They must be free of oil and grease.
– Clean sealing surfaces.
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spec
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wit
♦ Observe use-by-date of sealant.
♦ The sump must be installed within 5 minutes of applying sili‐
cone sealing compound.
♦ The sealant bead must not be thicker, otherwise excess seal‐
ing compound will enter the oil sump and may block the oil
suction line strainer.
– Cut off nozzle on tube of silicone sealant ⇒ Electronic Parts
Catalogue (ETKA) , at front marking (∅ of nozzle approx.
3 mm).
– Apply silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
to clean sealing surface of sump, as shown. Sealant bead
must
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♦ run along inner side of bolt holes -arrows-.
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– Apply silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
to clean sealing surface of sump, as shown in figure. (The fig‐
ure shows the position of the sealant bead on the cylinder
block.)
– Immediately position sump and tighten all sump bolts slightly.
Ensure that sump is flush against intermediate plate and gear‐
box flange.
Note
♦ The sump must be flush with cylinder block.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Tighten sump bolts in diagonal sequence.
– Tighten sump bolts at gearbox end using special wrench, long
reach - T10058- .
– Tighten bolts between sump and gearbox.
Specified torques
♦ ⇒ “1.1 Assembly overview - sump and oil pump”, page 95
98
Rep. gr.17 - Lubrication
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♦ be 2…3 mm thick.
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Installing
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.3
Engine oil
Note
♦ The oil level must not be above the max. mark - danger of
damage to catalytic converter!
♦ Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil channels.
♦ Renew oil spray jets.
♦ Renew engine oil cooler.
♦ Renew oil filter element.
Oil capacities:
Engine codes AXB and AXC
With oil filter 5.8 l
1) Top up to max. mark as necessary.
Engine codes BRR and BRS
With oil filter 6.3 l
AG. Volkswagen AG d
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Engine oil specifications:
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⇒ Maintenance
; Booklet 19
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Old version
1 - Max. mark
2 - Min. mark
a - Oil level in max. mark area: Do not replenish engine oil!
rrectness of i
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spec
at
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Markings on oil dipstick
b - Oil level in middle range: Can be replenished with engine oil.
c - Oil level in min. mark area: Replenish with max 0.5 l engine
oil!
New version
1 - Min. mark
2 - Max. mark
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a - Oil level in min. mark area: Replenish with approx. 0.5 l engine
oil!
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b - Oil level in middle range: Can be replenished with engine oil.
c - Oil level in max. mark area: Do not replenish engine oil!
1. Sump, oil pump
99
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AG.
Prote
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Oil filter, oil pressure switch
⇒ “2.1 Assembly overview - oil filter housing, oil pressure switch”,
page 100
⇒ “2.2 Checking oil pressure and oil pressure switch”,
page 101
⇒ “2.3 Measure oil consumption”, page 102
2.1
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Assembly overview
-goil
filter
housing,
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2 - Bolt
❑ Renew after removing.
❑ First fit upper left and
lower right bolts and
then tighten all 4 bolts in
diagonal sequence.
❑ 15 Nm + 90°
3 - Gasket
❑ Renew after removing.
4 - Seal
❑ Renew after removing.
5 - Union
❑ 35 Nm
10 - Oil pressure switch - F1❑ 0.7 bar switch: brown or
0.9 bar switch: grey
❑ If seal is leaking, nip open and renew.
❑ Checking ⇒ page 101 .
11 - Plug
❑ 25 Nm
12 - Gasket
❑ Renew after removing.
13 - Engine oil cooler
❑ Ensure clearance to adjacent components.
❑ See note ⇒ page 95 .
100
Rep. gr.17 - Lubrication
AG.
9 - Oil filter element
❑ Ensure "Top" is upper‐
most when fitting
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8 - O-ring
❑ Renew after removing.
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7 - Cap
❑ Loosen and tighten with
36 mm socket T10125- .
❑ 25 Nm
do
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6 - Oil supply line
❑ To turbocharger.
❑ Removing and installing
⇒ page 103 .
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
14 - Seal
❑ Renew after removing.
2.2
Checking oil pressure and oil pressure switch
Special tools and workshop
equipment required
pe
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♦ Voltage tester - V.A.G 1527
B-
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♦ Auxiliary measuring set V.A.G 1594C-
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♦ Oil pressure tester 1342-
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Test procedure
Note
Functional check and repair of the optical and acoustic oil pres‐
sure gauge: current flow diagrams ⇒ Vehicle diagnostic tester.
2. Oil filter, oil pressure switch
101
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove oil pressure switch - F1- and screw into tester.
– Screw tester into oil filter bracket in place of oil pressure
switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - V.A.G 1527 B- to battery positive (+)
and oil pressure switch using cables from auxiliary measuring
set - V.A.G 1594C- . LED must not light up.
– Start engine and increase revolutions slowly.
– At 0.55…0.85 bar the LED must light up, otherwise renew oil
pressure switch.
– Increase engine speed further. At 2,000 rpm and an oil tem‐
perature of 80°C the oil pressure should be at least 2.0 bar.
At higher engine speed, oil pressure must not exceed 7.0 bar. If
necessary renew oil filter bracket.
2.3
Measure oil consumption
– Manual gearbox: gear stick in neutral.
– Automatic gearbox: move selector lever to position “N”.
– Connect ⇒ Vehicle diagnostic tester.
– Switch ignition on.
AG.
Rep. gr.17 - Lubrication
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102
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– Choose program Oil consumption measurement using
⇒ Vehicle diagnostic tester and follow instructions.
rrectne
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spec
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– Pull handbrake on.
urposes, in part or in wh
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Procedure
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♦ Vehicle diagnosis tester
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Special tools and workshop equipment required
AG. Volkswagen AG d
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
⇒ “3.2
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3.1
AG. Volkswagen AG d
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Assembly overview - oil supply
line”,
page
103
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Removing and installing soil
au supply line”, page 103
c
s
Assembly overview - oil supply line
un
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⇒ “3.1
Oil circuit
2 - Retaining clamp
3.2
AG.
7 - Union nut
❑ 22 Nm
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6 - Nut
❑ 25 Nm
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5 - Bolt
❑ 10 Nm
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4 - Union nut
❑ 22 Nm
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3 - Oil supply line
❑ To turbocharger.
❑ Removing and installing
⇒ page 103 .
rrectne
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form
spec
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1 - Bracket
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3
Removing and installing oil supply line
Special tools and workshop equipment required
3. Oil circuit
103
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Torque wrench - V.A.G 1331-
– Unscrew securing bolts of retaining clip for oil supply line
⇒ Item 5 (page 103) .
– Unscrew union nuts of oil supply line on oil filter bracket
⇒ Item 7 (page 103) and exhaust turbocharger
⇒ Item 1 (page 133) or ⇒ Item 3 (page 135) .
– Remove oil supply line.
Installing
Installation is carried out in the reverse order; note the following:
Note
The procedure must be adhered to to ensure that the oil supply
line is installed tension-free.
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Rep. gr.17 - Lubrication
ht
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104
rrectness of i
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nf
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m
spec
atio
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wit
– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
thi
sd
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en
es, in part or in w
l purpos
hole
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Removing
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AG. Volkswagen AG d
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Transporter 2004 ➤
olkswaengine
gen AG - Edition 04.2013
AG. V
4-cylinder
diesel
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– Loosen securing bolts -6- of bracket -1-.
– Locate union nuts of oil supply line on connections.
– Hand-tighten union nut -7- on oil filter bracket.
– Hand-tighten union nut -4- on turbocharger.
– First tighten union nut -7- on oil filter bracket and then union
nut -4- on turbocharger.
Specified torques
♦ ⇒ “3.1 Assembly overview - oil supply line”, page 103
3. Oil circuit
105
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
19 –
Cooling
1
Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram - engine codes AXB and
AXC”, page 106
⇒ “1.2 Coolant hose schematic diagram - engine codes BRR and
BRS”, page 107
⇒ “1.3 Draining and filling coolant”, page 108
⇒ “1.4 Checking cooling system for leaks”, page 111
1.1
Coolant hose schematic diagram - engine codes AXB and AXC
1 - Heat exchanger for heater
unit
2 - 2nd heat exchanger for
heater unit
❑ Only if fitted with option‐
al equipment.
3 - Supplementary water heat‐
er (auxiliary heater or preheat‐
er)
❑ Depending on equip‐
ment.
4 - Circulation pump - V555 - Coolant expansion tank
6 - Engine oil cooler
es, in part or in w
l purpos
hole
ercia
, is n
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AG.
Rep. gr.19 - Cooling
thi
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106
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11 - Non-return valve
❑ Only with auxiliary cool‐
ant heater.
❑ Note installation posi‐
tion.
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10 - Heater coolant shut-off
valve - N279❑ Only with auxiliary cool‐
ant heater.
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9 - Cylinder head/cylinder
block
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8 - Coolant pump
AG. Volkswagen AG d
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7 - Radiator/cooler
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.2
Coolant hose schematic diagram - engine codes BRR and BRS
1 - Heat exchanger for heater
unit
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pe
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2 - 2nd heat exchanger for
heater unit
❑ Only if fitted with option‐
al equipment.
AG. Volkswagen AG d
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3 - Supplementary water heat‐
er (auxiliary heater or preheat‐
er)
❑ Depending on equip‐
ment.
4 - Circulation pump - V555 - Coolant expansion tank
7 - Radiator/cooler
8 - Coolant pump
9 - Cylinder block
10 - Cylinder head
11 - Exhaust gas recirculation
cooler
ht
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12 - Heater coolant shut-off
valve - N279❑ Only with auxiliary cool‐
ant heater.
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6 - Engine oil cooler
1. Cooling system, coolant
107
Transporter 2004 ➤
wagen AG
G. Volks04.2013
4-cylinder diesel engine
Edition
ge-n A
does
swa
Draining and filling coolant
not
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Special tools and workshop
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spec
at
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in t
his
♦ Refractometer - T10007 A♦ Drip tray for workshop hoist
- VAS 6208♦ Hose clip pliers - VAS
6340♦ Cooling system charge unit
- VAS 6096♦ Adapter for cooling system
tester - V.A.G 1274/8-
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WARNING
Steam may escape when expansion tank is opened. Wear eye
protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
– Open filler cap on coolant expansion tank.
– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
108
Rep. gr.19 - Cooling
do
c
um
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Draining
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove radiator outlet coolant temperature sender - G83-arrow-. To do this, pull retaining clip out of radiator flange.
es, in part or in w
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hole
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– In addition to draining coolant from engine, pull the coolant
hose off the engine oil cooler -arrow-.
rrectness of i
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Note
Observe environmental regulations for disposal.
Note
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Caution
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The amount of water used in the coolant mixture has a great in‐
fluence on its effectiveness. Because the water quality differs
from country to country and even region to region, Volkswagen
has decided to define the quality of the water to be used in the
coolant system. Distilled water fulfils all requirements. It is there‐
fore recommended that the coolant be mixed with distilled water
whenever the coolant is replenished or replaced, even for older
models.
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Filling
Only distilled water may be used for mixing with coolant addi‐
tives. The use of distilled water ensures optimum protection
against corrosion.
1. Cooling system, coolant
109
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
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Note
♦ Use only coolant additives which conform with the ⇒ Elec‐
rrectness of i
t to the co
nform
spec
at
i
h re
o
n
wit
in t
his
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 engine.
♦ The correct coolant solution ratio helps prevent damage due
to freezing and corrosion as well as scaling. Moreover, the
boiling temperature is raised. Therefore, the cooling system
must be filled all year round with coolant additive.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ Frost protection must be guaranteed down to about -25 °C (in
countries with Arctic climates, down to about -36 °C).
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♦ If a stronger anti-freeze mixture is necessary due to harsher
current anti-freeze density.
♦ Read anti-freeze figures from respective scale for type of anti-
freeze added.
♦ Do not reuse old coolant.
Recommended mixture ratios:
Frost protection Coolant additive Coolant ad‐ Distilled wa‐
to
portion
ditive 2)
ter2)
-25 °C
-36 °C
40 %
50 %
2.9 l
3.55 l
4.2 l
3.55 l
2) The quantity of coolant can vary depending upon vehicle equipment.
– Install coolant temperature sender at radiator outlet - G83- with
a new seal.
– Connect coolant hose -arrow- to engine oil cooler.
– Install any noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Noise insulation .
– Screw adapter - V.A.G 1274/8- onto coolant expansion tank.
– Fill coolant circuit with cooling system charge unit VAS 6096- . ⇒ Operating instructions for cooling system
charge unit VAS 6096
110
Rep. gr.19 - Cooling
AG.
♦ ONLY refractometer - T10007 A- may be used for determining
agen
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weather conditions, the coolant additive content can be in‐
creased. but only to 60 %, or the antifreeze protection will be
reduced again and the cooling effect will be impaired.
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ter even in warmer seasons and in warmer countries. The
coolant additive concentration must be at least 40%.
do
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♦ The coolant concentration must not be reduced by adding wa‐
Transporter 2004 ➤
diesel engine - Edition 04.2013
Checking cooling system for leaks
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♦ Cooling system tester V.A.G 1274 B♦ Adapter for cooling system
tester - V.A.G 1274/8-
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♦ Adapter for cooling system
tester - V.A.G 1274/9-
rrectne
s
s
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i
t to the co
n
form
spec
atio
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Special tools and workshop
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Test prerequisite
•
Engine at operating temperature.
•
Perform cooling system leakage test using cooling system
tester - V.A.G 1274 B- and adapter for cooling system tester V.A.G 1274/8- and adapter for cooling system tester - V.A.G
1274/9- .
Test procedure
WARNING
Steam may escape when expansion tank is opened. Wear eye
protection and protective clothing to avoid eye injuries and
scalding. Cover cap with cloth and open carefully.
– Open filler cap on coolant expansion tank.
– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
1. Cooling system, coolant
111
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
DANGER!
Risk of scalding! Before the cooling system tester - V.A.G 1274
B- is disconnected from the connecting hose or the connector
- V.A.G 1274 B/1- , reduction of the pressure is essential. To
do this, press pressure relief valve on cooling system tester V.A.G 1274 B- until pressure gauge displays value of »0«.
If pressure drops:
– Find leaks and rectify.
Checking pressure relief valve in filler cap
– Screw cap into adapter for cooling system tester - V.A.G
1274/9- .
– Screw connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/9- .
– Join connection piece - V.A.G 1274 B/1- to cooling system
tester - V.A.G 1274 B- using connecting hose supplied.
– Using hand pump on cooling system tester, build up a pres‐
sure of approx. 1.6 bar.
The pressure relief valve must not open.
If the pressure relief valve opens
prematurely:
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– Increase
bar.
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The pressure relief valve must open.
If the pressure relief valve does not open:
AG.
Rep. gr.19 - Cooling
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112
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– Renew cap.
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pressure
au
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– Renew cap.
⇒ “2.2 Removing and installing coolant pump”, page 114
⇒ “2.3 Removing and installing thermostat”, page 116
2.1
rrectne
s
s
o
f
i
t to the co
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form
spec
atio
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⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 113
Transporter 2004 ➤
engine - Edition 04.2013
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Coolant pump, regulation of cooling
system
un
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2
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Assembly overview - coolant pump, thermostat
1 - To coolant expansion tank
❑ Coolant hose schematic
diagram ⇒ page 106 .
2 - O-ring
❑ Renew after removing.
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4 - Coolant temperature send‐
er - G62❑ With coolant tempera‐
ture display sender G2- .
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3 - Retaining clip
❑ Check for secure seat‐
ing.
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5 - Supply
❑ To auxiliary water heat‐
er, for engine codes
AXB and AXC .
❑ To exhaust gas cooler
for engine codes BRR
and BRS
❑ Coolant hose schematic
diagram ⇒ page 106 .
6 - Union
7 - Bolt
❑ 10 Nm
8 - Return from heat exchanger
❑ Coolant hose schematic
diagram ⇒ page 106 .
9 - Bolt
❑ 40 Nm
10 - Coolant pipe
11 - Bolt
❑ 15 Nm
12 - To top of radiator
❑ Coolant hose schematic diagram ⇒ page 106 .
13 - To lower coolant expansion tank
❑ Coolant hose schematic diagram ⇒ page 106 .
14 - To bottom of radiator
❑ Coolant hose schematic diagram ⇒ page 106 .
2. Coolant pump, regulation of cooling system
113
Transporter 2004 ➤
4-cylinder diesel engine - Edition
04.2013
n AG. Volkswagen AG do
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15 - Union
❑ For thermostat.
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16 - Thermostat
❑ Checking: heat thermostat in water.
❑ Opening begins at approx. 87 °C.
❑ Ends at approx. 105 °C.
❑ Opening lift at least 7 mm.
❑ Note installation position ⇒ page 116 .
❑ Removing and installing ⇒ page 116 .
17 - Engine oil cooler
Removing and installing coolant pump
♦ Torque wrench - V.A.G
1331♦ Spring-type clip pliers VAS 5024A-
114
Rep. gr.19 - Cooling
AG.
♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- VAS 6208-
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♦ Refractometer - T10007 A-
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Special tools and workshop
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18 - Coolant pump
❑ Check for ease of movement.
❑ Note installation position.
❑ Removing and installing ⇒ page 114 .
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Removing
Note
Always renew gaskets and seals.
– Drain coolant ⇒ page 108 .
– Remove poly V-belt ⇒ page 17 .
– Removing, tensioning toothed belt (for vehicles ► 12.05)
⇒ page 65 .
– Removing, tensioning toothed belt, (for vehicles 01.06 ►)
⇒ page 73 .
– Remove coolant pump securing bolts -1- and carefully remove
coolant pump -2-.
Installing
Installation is carried out in the reverse order; note the following:
– Moisten new O-ring with coolant.
Note
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The coolant pump plug faces
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downwards.
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– Installing, tensioning toothed belt (for vehicles ► 12.05)
⇒ page 65 .
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
– Installing, tensioning toothed belt (for vehicles 01.06 ►)
⇒ page 73 .
– Install poly V-belt ⇒ page 17 .
– Replenish coolant ⇒ page 108 .
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 113
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 14
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 64
thi
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2. Coolant pump, regulation of cooling system
115
Prote
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2.3
Removing and installing thermostat
Special tools and workshop
equipment required
♦ Refractometer - T10007 A♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- VAS 6208♦ Torque wrench - V.A.G
1331-
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a
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wit
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s
Removing
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♦ Spring-type clip pliers VAS 5024A-
– Drain coolant ⇒ page 108 .
Vehicles with air conditioner
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Rep. gr.19 - Cooling
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116
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– Remove alternator ⇒ Rep. gr. 27
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Continuation for all vehicles
– Pull coolant hose off connection -2-.
– Remove connecting flange -2- securing bolts -1- and remove
connecting flange -2- with thermostat -4-.
– Turn thermostat -4- 1/4 turn (90°) to left and remove from con‐
necting flange -2-.
Installing
Installation is carried out in the reverse order; note the following:
Note
♦ Always renew gaskets and seals.
♦ The brace on the thermostat must be almost vertical.
– Moisten new O-ring -3- with coolant.
olkswagen AG
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– Insert thermostat -4- in union -2- and turn 1/4 turn
ksw(90°) to right.
Vol
– Fit connection -2- with
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– Tighten securing bolts -1-.
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thermostat a-4ut into cylinder
s
s
– Replenish coolant ⇒ page 108 .
rrectness of i
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nform
spec
at
i
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o
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wit
in t
his
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 113
♦ Alternator; Assembly overview - alternator ⇒ Alternator; Rep.
gr. 27 ; Assembly overview - alternator
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2. Coolant pump, regulation of cooling system
117
Prote
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Radiator, radiator fan
⇒ “3.1 Assembly overview - radiator, radiator fan”, page 118
⇒ “3.2 Removing and installing radiator”, page 119
3.1
Assembly overview - radiator, radiator fan
1 - Radiator/cooler
❑ After renewing, renew
entire coolant.
❑ Removing and installing
⇒ page 119 .
2 - Rubber bush
❑ For top of radiator.
3 - Bolt
❑ 10 Nm
4 - Upper coolant hose
❑ Coolant hose schematic
diagram ⇒ page 106 .
5 - Fan support
6 - Bolt
❑ 5 Nm
7 - Additional fan
❑ Vehicles with optional
equipment only.
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hole
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9 - Radiator fan
o
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10 - Coolant expansion tank
rrectness of i
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nf
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m
spec
atio
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n in
wit
❑ Check using cooling
system tester - V.A.G
1274- and adapter V.A.G 1274/8- .
11 - Bolt
❑ 5 Nm
12 - Cap
❑ Check using cooling
system tester V.A.G 1274- and adapter - V.A.G 1274/9- .
13 - Retaining clip
14 - Radiator outlet coolant temperature sender - G8315 - O-ring
❑ Renew if damaged.
Prote
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by
Rep. gr.19 - Cooling
AG.
118
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18 - Lower coolant hose
❑ Coolant hose schematic diagram ⇒ page 106 .
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17 - Retaining clip
❑ Check for secure seating.
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en
16 - Bracket
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
19 - Rubber bush
❑ For bottom of radiator
3.2
Removing and installing radiator
Special tools and workshop
equipment required
♦ Refractometer - T10007 A♦ Drip tray - V.A.G 1306- or
drip tray for workshop hoist
- VAS 6208♦ Torque wrench - V.A.G
1331-
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Removing
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♦ Spring-type clip pliers VAS 5024A-
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier - service po‐
sition .
AG.
– Remove charge air cooler ⇒ page 139 .
3. Radiator, radiator fan
119
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
rrectness of i
t to the co
nf
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m
spec
atio
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Note
The refrigerant lines remain connected to condenser.
– Drain coolant ⇒ page 108 .
– Remove radiator securing bolt -1- and push rubber mounting
in direction of arrow.
– Pull coolant hoses off radiator.
120
Rep. gr.19 - Cooling
AG.
– Lift condenser out of retainers -4- and -5- and place to side.
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– Remove condenser securing bolts -3-, -6- and -8-.
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– Unclip engine oil cooler and lay to one side.
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– Unscrew securing bolts -2- for engine oil cooler »servo oil«.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Separate connectors -arrows- for fan on radiator fan control
unit - J293- .
– Carefully remove radiator to side.
Installing
Installation is carried out in the reverse order; note the following:
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator, radiator fan”, page 118
♦ ⇒ “2.1 Assembly overview - charge air system”, page 139
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♦ Lock carrier; Assembly overview - lock carrier ⇒ Lock carrier;
Rep. gr. 50 ; Assembly overview - lock carrier
3. Radiator, radiator fan
121
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
20 –
Fuel supply system
1
Fuel tank
⇒ “1.1 Assembly overview - fuel tank”, page 122
⇒ “1.2 Removing and installing fuel tank”, page 124
1.1
Assembly overview - fuel tank
Caution
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
urposes, in part or in wh
ole,
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3 - Earth connection
❑ Check for secure seat‐
ing.
Rep. gr.20 - Fuel supply system
AG.
122
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7 - Supply line
❑ To fuel filter
⇒ page 129 or
⇒ page 130
❑ Clipped onto fuel tank.
❑ Check for secure seating.
❑ Black
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6 - Union nut
❑ Remove and install us‐
ing union nut tool 3217- .
❑ 80 Nm
ht
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5 - Fuel system pressurisation
pump - G6- and fuel gauge
sender - G- .
❑ Note installation posi‐
tion on fuel tank
⇒ page 123 .
❑ To remove, first remove
fuel tank ⇒ page 124 .
❑ Removing and installing
fuel gauge sender
⇒ page 127 .
r
fo
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4 - Seal
❑ Renew if damaged.
❑ Moisten with fuel when
installing
rrectne
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2 - Bush
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1 - Fuel tank
❑ Drain fuel tank using
fuel extractor - VAS
5190❑ Removing and installing
⇒ page 124 .
un
le
The fuel tank must contain at least 5 litres of fuel.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑ To pull off flange, press release button on connecting piece.
8 - Return line
❑ From fuel cooler.
❑ Blue or with blue marking.
❑ Clipped onto fuel tank.
❑ Check for secure seating.
❑ To pull off flange, press release button on connecting piece.
9 - Bolt
❑ 12 Nm
10 - Rubber cup
11 - Securing bolt
12 - Cap
❑ Renew seal if damaged.
13 - Bolt
❑ 20 Nm
14 - Securing strap
❑ Note installation position.
❑ Check for secure seating.
15 - Return line
❑ From fuel filter ⇒ page 129 or vacuum pump
❑ Blue or brown
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❑ Check for secure seating.
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❑ To pull off flange,
press release button on connecting piece.
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Installation position of fuel gauge sender
Marking on sender flange must align with the marking on fuel tank
-arrows-.
Connections for blue or blue-marked return line -1- and black
supply line -2- are marked with an arrow on fuel gauge sender
flange.
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18 - Wiring harness
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17 - Return line
❑ Blue or brown
❑ Check for secure seating.
❑ To pull off flange, press release button on connecting piece.
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16 - Fuel coolerss a
❑ Not in case of vehicles without fuel preheating
❑ Removing and installing ⇒ page 128 .
After installing fuel gauge sender, check whether fuel supply and
return lines are still clipped onto fuel tank.
1. Fuel tank
123
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.2
Removing and installing fuel tank
Caution
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
Special tools and workshop
equipment required
♦ Union nut tool - 3217-
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♦ Fuel tank must be drained. Use the fuel extractor - VAS 5190-
to do this.
♦ Before carrying out further work, disconnect battery earth
strap. For this reason, check whether a coded radio is fitted.
Obtain anti-theft coding first if necessary.
– Note safety precautions before starting installation work
⇒ page 3 .
124
Rep. gr.20 - Fuel supply system
rrectness of i
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Note
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Removing
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♦ Fuel extractor - VAS 5190-
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♦ Engine and gearbox jack V.A.G 1383 A-
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♦ Torque wrench - V.A.G
1332-
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♦ Torque wrench - V.A.G
1331-
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Observe rules for cleanliness ⇒ page 5 .
– Open fuel tank flap and remove fuel tank cap.
– Drain fuel tank and clean fuel filler neck and surrounding area.
– Remove securing bolt, then pull rubber cup off filler neck and
remove.
– Unscrew securing bolt of filler neck.
– Remove lower cover with heat shield -A-.
rrectness of i
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1. Fuel tank
125
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Disconnect supply line -1- and return line -2-.
Note
♦ Press in buttons on hose couplings to do this.
♦ On vehicles with auxiliary heater disconnect additional fuel
line.
– Remove fuel cooler if there is one.
– Remove securing straps. When doing this, support fuel tank
with engine and gearbox jack - V.A.G 1383 A- .
– Lower engine and gearbox jack - V.A.G 1383 A- just enough
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– Lower fuel
ss tank.
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Installing
Installation is carried out in the reverse order; note the following:
The fuel pump must not be allowed to run when the fuel tank
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
rrectne
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Caution
♦ Connections for breather and fuel lines must engage audibly
when joined.
♦ Clip fuel lines onto fuel tank.
♦ Push connector onto fuel pump flange and clip wire onto fuel
tank.
♦ Ensure that fuel hose connections are tight.
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♦ ⇒ “1.1 Assembly overview - fuel tank”, page 122
AG.
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Rep. gr.20 - Fuel supply system
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126
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Specified torques
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Fuel delivery unit, fuel gauge sender
⇒ “2.1 Removing and installing fuel gauge sender G ”,
page 127
2.1
Removing and installing fuel gauge
sender - G-
Removing
– Remove fuel tank ⇒ page 124 .
– Remove fuel system pressurisation pump - G6- .
– Release connector lugs on lines -3- and -4- and pull off.
– Lift retaining tabs -1- and -2- using a screwdriver and pull fuel
gauge sender off downwards -arrows-.
Installing
Installation is carried out in the reverse order; note the following:
– Insert fuel gauge sender - G- into guides on fuel pump and
press upwards until it engages.
Specified torques
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♦ ⇒ “1.1 Assembly overview - fuel tank”, page 122
2. Fuel delivery unit, fuel gauge sender
127
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Fuel cooler
⇒ “3.1 Removing and installing fuel cooler”, page 128
3.1
Removing and installing fuel cooler
On vehicles without fuel preheating a fuel cooler is not installed.
Special tools and workshop equipment required
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Removing
Observe rules for cleanliness ⇒ page 5 .
Note
The fuel cooler is located in the return line to fuel tank. It is in‐
stalled on underbody of vehicle.
– Remove underbody trim.
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– Unscrew securing bolts -arrows-.
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♦ Torque wrench - V.A.G 1331-
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– Pull fuel cooler downwards and detach fuel lines -arrows- at
fuel cooler.
Installing
Installation is carried out in the reverse order; note the following:
Specified torque
Component
Specified torque
Securing bolts for fuel cooler
20 Nm
128
Rep. gr.20 - Fuel supply system
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
4
Fuel filter
es, in part or in w
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hole
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⇒ “4.1 Assembly overview - fuel
page 129
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filter
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⇒ “4.2 Assembly overview - fuel filter”, page 130
4.1
Note
rrectness of i
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spec
atio
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wit
Assembly overview - fuel filter with fuel
preheating
To guarantee immediate engine starting after renewing fuel filter,
the fuel system must be bled ⇒ Maintenance ; Booklet 19.1
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2 - Return line
❑ To fuel cooler
⇒ page 128
❑ Clipped on fuel filter,
identification -RT❑ To pull off, press release
button on connection.
❑ Check for secure seat‐
ing.
❑ Blue or with blue mark‐
ing.
ht
rig
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Co
t.
1 - Securing clip
3 - Supply line
❑ From fuel tank.
❑ Clipped on fuel filter,
identification -VF❑ To pull off, press release
button on connection.
❑ Check for secure seat‐
ing.
❑ Black
4 - Bolt
❑ 18 Nm
5 - Bracket
6 - Nut
❑ 18 Nm
7 - Fuel filter
❑ Note installation posi‐
tion on bracket
⇒ Item 5 (page 129) .
8 - Seal
❑ Renew after removing.
9 - Water drain screw
❑ To drain water, connect hand vacuum pump and attachments - V.A.G 1390- and drainage container V.A.G 1390/1- and extract approx. 100 cm3 of fluid.
❑ 4 Nm
4. Fuel filter
129
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
10 - Supply line
❑ To vacuum pump
❑ Clipped on fuel filter, identification -VM❑ To pull off, press release button on connection.
❑ Check for secure seating.
❑ Black
11 - Return line
❑ From vacuum pump
❑ Clipped on fuel filter, identification -RF❑ To pull off, press release button on connection.
❑ Check for secure seating.
❑ Blue or with blue marking.
4.2
Assembly overview - fuel filter
Note
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Rep. gr.20 - Fuel supply system
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130
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To guarantee immediate engine starting after
tee
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or
the fuel system must be bled ⇒ Maintenance
; Booklet 19.1
u
ac
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
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Prote
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8 - Bracket
❑ For fuel hoses
AG.
7 - Bracket
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6 - Bolt/nut
❑ 18 Nm
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5 - Bolt
❑ 9 Nm
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wit
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4 - Bracket
❑ For fuel filter.
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3 - Fuel filter
❑ Observe change inter‐
vals.
❑ Note installation posi‐
tion.
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2 - Supply line
❑ From fuel tank.
❑ Black
❑ Union with marking VF-.
❑ Check for secure seat‐
ing.
❑ To pull off, press release
button on connection.
un
le
1 - Supply hose
❑ To vacuum pump
❑ Union with marking VM-.
❑ Check for secure seat‐
ing.
❑ To pull off, press release
button on connection.
4. Fuel filter
131
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
5
Accelerator mechanism
⇒ “5.1 Assembly overview - accelerator mechanism”, page 132
5.1
Assembly overview - accelerator mechanism
1 - Bearing bracket
❑ Removing and installing
⇒ Brake system; Rep.
gr. 46 ; Brake pedal;
Removing and installing
- brake pedal
2 - Connector
❑ Black, 6-pin.
3 - Nut
❑ 10 Nm
4 - Accelerator position sender
- G79❑ Not adjustable.
. Volkswagen AG
❑ The accelerator position
gen AG
does
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Rep. gr.20 - Fuel supply system
do
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132
ac
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a
ss
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
21 –
Turbocharging/supercharging
1
Turbocharger
⇒ “1.1 Assembly overview - turbocharger, engine codes AXB and
AXC”, page 133
⇒ “1.2 Assembly overview - turbocharger, engine codes BRR and
BRS”, page 135
⇒ “1.3 Removing and installing turbocharger”, page 137
1.1
Assembly overview - turbocharger, engine codes AXB and AXC
1 - Exhaust manifold
❑ With exhaust turbo‐
charger
❑ Only renew complete
2 - From charge air cooler
3 - Intake manifold
es, in part or in w
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hole
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atio
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5 - Bolt
❑ 25 Nm
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4 - Gasket
❑ Renew after removing.
❑ Coating (beading) to‐
wards intake manifold
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6 - Gasket
❑ Renew after removing.
❑ Note installation posi‐
tion.
7 - Bolt
❑ 25 Nm
8 - Support
❑ Between turbocharger
and cylinder block.
AG.
13 - Nut
❑ 25 Nm
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11 - Heat shield
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10 - Nut
❑ 25 Nm
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9 - Washer
1. Turbocharger
133
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
14 - From pressure regulating valve
15 - From air filter.
16 - Connecting hose
rrectness of i
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20 - Seal
❑ Renew after removing.
21 - Union
❑ 40 Nm
22 - Oil return line
❑ To cylinder block.
❑ Union nut - 22 Nm
23 - Bolt
❑ 17 Nm
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25 - To charge air cooler
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26 - Turbocharger
❑ Can only be renewed with exhaust manifold.
❑ Removing and installing ⇒ page 137 .
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24 - Gasket
❑ Renew after removing.
AG.
Prote
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by
27 - Vacuum hose
❑ To charge pressure control solenoid valve - N75- schematic diagram ⇒ page 151 .
28 - Vacuum unit
❑ For charge pressure control.
❑ Part of turbocharger.
29 - Bolt
❑ First hand tighten all bolts
❑ 20 Nm
30 - Clip
❑ 7 Nm
31 - Gasket
❑ Renew after removing.
❑ Note installation position.
32 - Front exhaust pipe
33 - Seal
❑ Renew after removing.
34 - Union
❑ Renew after removing.
❑ Coat threads and bolt head seating surface with high-temperature paste ⇒ Electronic Parts catalogue
(ETKA) .
❑ 30 Nm
35 - Oil supply line
❑ Before installing oil supply line, ensure that it is not blocked.
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
134
Rep. gr.21 - Turbocharging/supercharging
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑ Removing and installing ⇒ page 103 .
36 - Bolt
❑ 10 Nm
❑ Removing and installing oil supply line ⇒ page 103
37 - Retaining clamp
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❑ Removing and installingolkoil
swasupply line ⇒ page 103
no
38 - Nut
❑ 25 Nm
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40 - Connecting pipe
❑ To intake connecting pipe.
41 - Gasket
❑ Renew after removing.
1.2
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39 - Bracket
❑ For oil supply line ⇒ Item 35 (page 134) .
❑ Secure oil supply line before fitting it.
Assembly overview - turbocharger, engine codes BRR and BRS
1 - Nut
❑ 20 Nm
AG.
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4 - Exhaust gas temperature
sender 1 - G235❑ For vehicles with partic‐
ulate filter.
❑ Grease thread of sender
using high-temperature
paste ⇒ Electronic
Parts Catalogue (ET‐
KA) .
❑ 45 Nm
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3 - Exhaust manifold
❑ With exhaust turbo‐
charger
❑ Only renew complete
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2 - Gasket
❑ Renew after removing.
5 - Gasket
❑ Renew after removing.
❑ Note installation posi‐
tion.
6 - Bolt
❑ 25 Nm
7 - Support
❑ Between turbocharger
and cylinder block.
8 - Washer
9 - Nut
❑ 25 Nm
1. Turbocharger
135
Transporter 2004 ➤
n AG. Volkswagen AG do
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4-cylinder diesel engine - Edition 04.2013
o
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10 - Heat shield
un
le
13 - Connecting hose
14 - Spring-type clip
15 - Connecting piece
16 - Seal
❑ Renew after removing.
17 - Union
❑ 40 Nm
21 - Turbocharger
❑ Can only be renewed with exhaust manifold.
❑ Removing and installing ⇒ page 137 .
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20 - To charge air cooler
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19 - Bolt
❑ 17 Nm
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fo
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18 - Oil return line
❑ To cylinder block.
❑ Union nut - 22 Nm
rrectne
s
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o
f
i
t to the co
n
form
spec
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11 - From pressure regulating
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22 - Vacuum hose
❑ To charge pressure control solenoid valve - N75- , schematic diagram ⇒ page 152 or ⇒ page 153 .
AG.
23 - Vacuum unit
❑ For charge pressure control.
❑ Part of turbocharger.
24 - Bolt
❑ First hand tighten all bolts
❑ 20 Nm
25 - To particulate filter
❑ ⇒ Item 10 (page 162)
❑ To front exhaust pipe on vehicles without particulate filter ⇒ Item 3 (page 158) .
26 - Union
❑ Renew after removing.
❑ Coat threads and bolt head seating surface with high-temperature paste ⇒ Electronic Parts catalogue
(ETKA) .
❑ 30 Nm
27 - Oil supply line
❑ Before installing oil supply line, ensure that it is not blocked.
❑ Before installing, fill turbocharger with engine oil through oil supply line connection.
❑ Removing and installing ⇒ page 103 .
28 - Bolt
❑ Removing and installing oil supply line ⇒ page 103
❑ 10 Nm
29 - Retaining clamp
❑ For oil supply line ⇒ Item 27 (page 136) .
30 - Nut
❑ 25 Nm
136
Rep. gr.21 - Turbocharging/supercharging
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
31 - Bracket
❑ For oil supply line ⇒ Item 27 (page 136) .
❑ Secure oil supply line before fitting it.
32 - Connecting pipe
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gen AG ⇒ Item 5n(page
❑ To exhaust gas recirculation
cooler
does168) .
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Removing and installing turbocharger
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1.3
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Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
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♦ All hose connections are secured.
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♦ Renew self-locking nuts.
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♦ Charge air system must be free of leaks.
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Note
♦ Before screwing on oil supply line, fill turbocharger at connec‐
AG.
Prote
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by
tion with engine oil.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
Observe rules for cleanliness ⇒ page 5 .
Caution
When a mechanical fault is found on the turbocharger, e.g. a
destroyed compressor impeller, it is not only sufficient to renew
the turbocharger. To prevent this from causing further damage,
perform the following repairs:
♦ Check air filter housing, air filter element and intake hoses
for soiling.
♦ Check complete charged air routing and charge air cooler
for foreign objects.
If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
be renewed, if necessary.
Removing
Vehicles with particulate filter
– Remove particulate filter ⇒ page 163 .
1. Turbocharger
137
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Separate connector from exhaust gas temperature sender 1 G235- and open cable ties of wiring harness.
Vehicles without particulate filter
– Remove front exhaust pipe ⇒ page 158 .
Continuation for all vehicles
– Remove connecting hoses ⇒ Item 16 (page 134) and
⇒ Item 13 (page 136) .
– Remove oil supply line ⇒ page 103 .
– Pull vacuum hose off turbocharger vacuum unit.
– Remove exhaust gas recirculation connecting pipe.
– Unbolt oil return line -2- from cylinder block.
– Unscrew securing bolt of turbocharger -1-.
– Unscrew securing nuts of heat shield and exhaust manifold.
– Remove turbocharger with exhaust manifold downwards.
Installing
Installation is carried out in the reverse order; note the following:
Engine codes AXB and AXC
– Install oil supply line ⇒ Item 3 (page 103) .
Engine codes BRR and BRS
– Install oil supply line ⇒ page 103 .
– Observe installation instructions for particulate filter
⇒ page 163 .
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Continuation for all engine codes
– Checking engine oil level.
♦ ⇒ “1.1 Assembly overview - turbocharger, engine codes AXB
and AXC”, page 133
rrectness of i
t to the co
nf
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m
spec
atio
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n in
wit
♦ ⇒ “1.2 Assembly overview - turbocharger, engine codes BRR
and BRS”, page 135
♦ ⇒ “1.1 Assembly overview - silencers/catalytic converters”,
page 158
♦ ⇒ “1.2 Assembly overview - silencers/particulate filter”,
page 159
agen
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Rep. gr.21 - Turbocharging/supercharging
ht
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138
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Specified torques
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Charge air system
⇒ “2.1 Assembly overview - charge air system”, page 139
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 140
⇒ “2.3 Checking charge air system for leaks”, page 141
2.1
Assembly overview - charge air system
1 - Intake manifold flap motor V1572 - Securing clip
3 - O-ring
❑ Renew after removing.
❑ Black
4 - Connecting hose
5 - Connecting pipe
6 - Connecting hose
7 - Charge air cooler
❑ To remove and install,
remove bumper cover
⇒ General body repairs,
exterior; Rep. gr. 63 ;
Front bumper cover .
8 - Bolt
❑ 8 Nm
17 - Bolt
❑ 10 Nm
AG.
16 - Connecting pipe
❑ Secured to engine bracket.
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15 - Connecting hose
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14 - From turbocharger
ht
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13 - Bolt
❑ 3 Nm
r
fo
ng
12 - Intake manifold pressure
sender - G71- with intake
manifold temperature sender G72❑ For engine codes BRR
and BRS: intake air tem‐
perature sender - G42with charge pressure sender - G31- .
2. Charge air system
rrectne
s
s
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f
i
t to the co
n
form
spec
atio
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11 - Connecting hose
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10 - O-ring
❑ Renew after removing.
un
le
9 - O-ring
❑ Renew after removing.
❑ Green
139
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Note
♦ Charge air system must be free of leaks.
♦ For assembly use lubricant (water without additive) if neces‐
sary. Do not use lubricants containing oil.
lkswagen AG
AG. Voconnection
en from
♦ When making repairs, remove
goil
dand
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swa
ends.
♦
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All hose connections
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a or by connector couplings. Always check the
spring-type clips
c
ss
♦ Release connection by pulling the locking clip -arrow-.
♦ Pull hose/pipe connection off without the use of tools.
2.2
Assembly overview - charge-air hose
connections
Caution
The seal in the plug-in connector can be damaged if the se‐
curing clip is in the locked position when fitting the connector.
This can cause leakage.
Observe installation instructions.
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– Release plug-in connector by pulling out retaining clip
-arrow-.
AG.
Prote
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by
Installing
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– Separate hose/pipe without tools.
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Removing
Installation is carried out in the reverse order; note the following:
– If renewed, place oil seal in groove of charge air hose.
– Make sure seal is completely slotted into the groove all round.
– Coat sealing surfaces and oil seal with oil.
140
Rep. gr.21 - Turbocharging/supercharging
rrectness of i
t to the co
nf
o
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m
spec
atio
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wit
♦ When installing, ensure the locking lugs -A- engage correctly.
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following points with push-on connectors:
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– 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.
– By pulling on hose, check whether connector coupling seats
correctly and is properly engaged.
2.3
Checking charge air system for leaks
Special tools and workshop equipment required
♦ 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.
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Insert adapter - V.A.G 1687/10- intoedintake
hose -1- and se‐
by
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cure with a clip.
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Detach hose from crankcasesbreather system valve and seal.
rrectness of i
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nform
spec
a
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Prepare charge air system tester - V.A.G 1687- as follows:
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To turn the pressure regulating valve -2- the knob must be pulled
upwards.
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Note
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– Unscrew pressure control valve -2- completely and close
valves -3- and -4-.
2. Charge air system
141
AG.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Connect charge air system tester - V.A.G 1687- to adapter V.A.G 1687/10- as shown.
– Connect compressed air hose -1- (compressed air supply) to
charge air system tester - V.A.G 1687- .
Note
If water is in inspection glass, drain via drain screw -6-.
– Open valve -3-.
– Adjust pressure to 0.5 bar with pressure control valve -2-.
Caution
The pressure must not exceed 0.5 bar! .IfVothe
is too
lkswpressure
agen AG
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high this can cause damage tokthe
swa engine.
n
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– Check charge air system for leaks by listening, touching, with
commercially available leak detector spray or using ultrasonic
tester - V.A.G 1842- .
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–
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Open valve -4- and
a
ss to 0.5 bar.
regulate pressure
Note
♦ How to use the ultrasonic tester - V.A.G 1842- ⇒ operating
instructions
♦ If a leak has been located, observe notes for charge air system
when carrying out any repair work ⇒ page 139 ..
♦ Depressurise test circuit by detaching coupling from adapter -
agen
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Rep. gr.21 - Turbocharging/supercharging
ht
rig
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142
do
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V.A.G 1687/10- before removing adapter.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
23 –
Mixture preparation - injection
1
Injectors
. Volkswagen AG
gen AG
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⇒ “1.1 Assembly overview
ks-winjectors”, page 143 es not
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⇒ “1.2 Removingorand
ise installing O-rings for unit injector”, ante
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page 144
ra
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⇒ “1.3 Removing and installing injectors”, page 146
⇒ “1.4 Removing and installing prewiring for unit injectors”, page
148
Assembly overview - injectors
♦ Observe rules for cleanliness ⇒ page 5 .
♦ Always renew seals and O-rings
1 - Bolt
❑ Renew after removing.
❑ 20 Nm + 90°
2 - Rocker arm shaft
❑ With rocker arms
❑ Removing and installing
⇒ page 146 .
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4 - Adjuster screw
❑ Renew after removing.
❑ Observe notes on re‐
newing ⇒ page 146
ht
rig
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3 - Lock nut
❑ 30 Nm
rrectne
s
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o
f
i
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form
spec
atio
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i
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thi
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1.1
Prote
cted
by
5 - Ball stud
❑ Renew after removing.
❑ Observe notes on re‐
newing ⇒ page 146
6 - Unit injector
❑ Removing and installing
⇒ page 146 .
7 - O-ring
❑ Renew. ⇒ page 144 .
8 - O-ring
❑ Renew. ⇒ page 144 .
9 - O-ring
❑ Renew. ⇒ page 144 .
10 - Heat shield seal
❑ Renew after removing.
1. Injectors
143
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
11 - Circlip
12 - Cylinder head
13 - Tensioning block
14 - Bolt
❑ Renew after removing.
❑ 12 Nm + 270° further
1.2
Removing and installing O-rings for unit
injector
. Volkswagen AG
AGrequired
Special tools and workshop equipment
do
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♦ Assembly sleeves - T10056by
ed
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spec
atio
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wit
Removing
– Lever old O-rings very carefully out of unit injector.
– Pay particular attention to ensure that seat of O-ring is not
damaged by burrs.
Installing
Note
♦ Always use the assembly sleeves to fit the O-rings. There is a
ht
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danger of damaging the O-rings if the sleeves are not used.
♦ Gradual introduction of O-rings without different coloured
agen
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Prote
cted
by
markings. Note the correct allocation of O-rings to grooves:
the thickness of the rings reduces towards injector nozzle.
AG.
♦ Avoid any rolling movement when pushing O-rings on. The O-
rings must not be twisted in their seats in unit injector.
– Remove heat shield seal together with circlip.
– Clean seating surfaces for O-rings on unit injector very care‐
fully.
144
Rep. gr.23 - Mixture preparation - injection
thi
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es, in part or in w
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ss
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– 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.
– Remove assembly sleeve.
– Slide assembly sleeve - T10056/2- onto unit
stop.
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– Remove assembly sleeve.
– Slide assembly sleeve - T10056/3- onto unit injector as far as
stop.
– Push lower O-ring carefully onto assembly sleeve and into
seat on unit injector.
– Remove assembly sleeve.
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– Slide new heat shield seal together with circlip into position.
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– Push middle, thinner O-ring carefully onto assembly sleeve
and into seat on unit injector.
145
AG.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1.3
Removing and installing injectors
Special tools and workshop
equipment required
♦ Universal dial gauge brack‐
et - VW 387♦ Socket XZN 10 - 3410♦ Special wrench, long reach
XZN 6 - T10054-
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– Loosen lock nuts of adjustment screws -1- and remove ad‐
justment screws.
– Loosen securing bolts -2- for rocker arm shaft working from
outside to inside using Socket XZN 10 - 3410- . Remove rocker
arm shaft.
– 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.
Observe cylinder allocation of unit injectors.
146
Rep. gr.23 - Mixture preparation - injection
AG.
– Turn crankshaft until the cam pair of the respective unit injector
to be removed evenly points upwards.
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– Remove upper part of toothed belt guard and cylinder head
cover.
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♦ Torque wrench - V.A.G
1331-
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♦ Puller - T10055-
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Insert puller - T10055- in place of clamping block into slot on
side of unit injector.
– Pull unit injector upwards out of cylinder head seat by means
of gentle tapping.
Installing
Installation is carried
un
le
is performed which requires adjustment of the unit injector, the
adjustment screws ⇒ Item 4 (page 143) and the ball pins
⇒ Item 5 (page 143) of the unit injectors must be renewed.
♦ New unit injectors are supplied with O-rings and heat shield
seal.
♦ The seals must not be twisted.
– If old unit injector is reused, renew heat insulation seal and Orings ⇒ page 144 .
– Check that 3 O-rings, heat shield seal and circlip are seated
correctly before installing unit injector.
– Lubricate oil seals and insert unit injector into cylinder head
with great care.
– Insert clamping block in slot on side of unit injector.
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– Apply even pressure to push unit injector into cylinder head
seat as far as stop.
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If the unit injector is not at right angles to the tensioning block the
securing bolt may loosen and this can damage the unit injector or
the cylinder head.
– Thus, 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).
– Align unit injector at right angles to camshaft bearing seats.
– Check dimension “a” from outer edge of cylinder head to roun‐
ded edge of unit injector with a vernier gauge (measuring
range at least 400 mm).
Cylinder
Dimension “a”
1
2
3
4
333.0 ± 0.8 mm
245.0 ± 0.8 mm
153.6 ± 0.8 mm
65.6 ± 0.8 mm
– Realign unit injector if necessary and tighten securing bolt.
– Renew unit injector ball studs ⇒ Item 5 (page 143) .
1. Injectors
147
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Fit rocker arm shafts with new adjustment screws and tighten
new securing bolts as follows:
– First tighten inner bolts -2- then outer bolts -1- by hand. Tighten
in same sequence.
– Fit dial gauge onto adjustment screw of unit injector as shown.
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– Turn crankshaft in direction of engine w
rotation
roller
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rocker arm is located at tip of drive
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-arrow A- positioned at highest
point,
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gauge
-arrow
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– Now turn adjustment screw into rocker arm until significant re‐
sistance can be felt (unit injector is at limit stop).
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– Remove dial gauge.
– Slacken adjustment screw of stop by 180°.
– Hold adjuster bolt in this position and tighten lock nut.
– Fit unit injector connector and install cylinder head cover
⇒ page 53 .
– Install toothed belt guard.
– Read event memory ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
Removing and installing prewiring for
unit injectors
Prote
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148
Rep. gr.23 - Mixture preparation - injection
AG.
♦ Puller - T10312-
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Special tools and workshop equipment required
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♦ ⇒ “1.1 Assembly overview - injectors”, page 143
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
♦ Wrench - T10310-
Removing
Caution
Removal and installation of the pre-wired wiring harness may
. Volkswage
only be undertaken by unscrewing the clips. Releasing
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Connectors on piezo unit injectors may only be disconnected us‐
ing special tool puller - T10312- .
– Remove cylinder head cover ⇒ page 53 .
– Disconnect central connector on cylinder head.
– Remove both bolts of central connector on cylinder head.
– Fit special wrench - T10310- on adapter ring and release it by
turning key through 90° (1/4 turn) in -direction of arrow-.
do
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1. Injectors
149
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– If fitted, pull securing clip -1- upwards slightly with a screw‐
driver and press central connector -2- through inwards.
– Slide the puller - T10312- onto the unit injector connector from
the side and pull it off in -direction of arrow-. Use long-nosed
pliers for the older connector version.
– Pull pre-wiring harness out of cylinder head.
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h
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– Guide pre-wiring harness into cylinder head, ensure sclips seat
rrectness of i
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spec
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securely in cylinder head.
– Fit central connector to cylinder head and lock in position.
– Install cylinder head cover ⇒ page 53 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
Component
Specified torque
Threaded connections for wir‐
ing harness.
10 Nm
150
Rep. gr.23 - Mixture preparation - injection
AG.
When adapter ring is installed correctly the colour marked “short‐
er” stud faces 12 o'clock.
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– Secure central connector bolts to cylinder head.
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– Fit special wrench - T10310- on adapter ring and lock it by
turning key through 90° (1/4 turn) in opposite
-direction of arrow-.
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– Fit adapter ring (colour marked “longer” stud -arrow- faces 12
o'clock)
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Vacuum system
⇒ “2.1 Vacuum system schematic diagram - engine codes AXB
and AXC”, page 151
⇒ “2.2 Vacuum system schematic diagram - engine codes BRR
and BRS, ► 2007”, page 152
⇒ “2.3 Vacuum system schematic diagram - engine codes BRR
and BRS, 2008 ►”, page 153
2.1
Vacuum system schematic diagram - engine codes AXB and AXC
1 - Vacuum unit
2 - Variable intake manifold
flap changeover valve - N2394 - Non-return valve
13 - Vacuum unit
❑ For charge pressure
control.
❑ Integral part of turbo‐
charger and cannot be
replaced individually.
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12 - Vacuum reservoir
urposes, in part or in wh
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11 - Charge pressure control
solenoid valve - N75-
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10 - Mechanical exhaust gas
recirculation valve
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8 - Junction
❑ With non-return valve
for brake servo.
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7 - Brake servo
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6 - Exhaust gas recirculation
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5 - Filter
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3 - Junction
2. Vacuum system
151
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2.2
Vacuum system schematic diagram - engine codes BRR and BRS, ► 2007
1 - Charge pressure control
solenoid valve - N752 - Vacuum reservoir
3 - Brake servo line
4 - Non-return valve
❑ Note installation posi‐
tion.
❑ Black connection faces
brake servo line
⇒ Item 3 (page 152)
5 - Air filter
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Rep. gr.23 - Mixture preparation - injection
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152
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6 - Turbocharger
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Vacuum system schematic diagram - engine codes BRR and BRS, 2008 ►
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6 - Turbocharger
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4 - Vacuum reservoir
❑ In cylinder head cover.
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3 - Brake servo line
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2 - Non-return valve
❑ Note installation posi‐
tion.
❑ Black connection faces
brake servo line
⇒ Item 3 (page 153)
un
le
1 - Charge pressure control
solenoid valve - N75-
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2.3
2. Vacuum system
153
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Air filter
⇒ “3.1 Assembly overview - air filter”, page 154
Assembly overview - air filter
1 - Air mass meter - G70-
9 - To turbocharger.
10 - Spring-type clip
12 - From crankcase breather/
cylinder head cover
13 - Intake hose
❑ To turbocharger.
14 - Bolt
❑ 6 Nm
154
Rep. gr.23 - Mixture preparation - injection
thi
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11 - Air duct
❑ To lock carrier.
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8 - Bolt
❑ 8 Nm
AG.
7 - Rubber bush
❑ Clipped into lower part
of air filter
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2 - O-ring
❑ Renew if damaged.
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3.1
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
4
Intake manifold
⇒ “4.1 Assembly overview - intake manifold, engine codes BRR
and BRS”, page 155
⇒ “4.2 Assembly overview - intake manifold, engine codes AXB
. Volkswagen AG
gen AG
and AXC”, page 155
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6 - Gasket
❑ Renew after removing.
❑ Note installation posi‐
tion.
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5 - From exhaust gas recircu‐
lation cooler
❑ ⇒ Item 5 (page 168)
do
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4 - Intake manifold
❑ To remove, remove ex‐
haust gas recirculation
cooler ⇒ page 168 and
heat shield plate
⇒ Item 10 (page 136) .
c
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3 - Seal
❑ Renew if damaged.
rrectness of i
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nform
spec
at
i
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his
2 - Intake manifold flap motor V157❑ The intake manifold flap
is closed for approx. 3
seconds when stopping
engine and then opens
again. This reduces the
stop jolt.
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1 - Bolt
❑ 9 Nm
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7 - Bolt
❑ 20 Nm
8 - Exhaust gas recirculation
valve - N18- with exhaust gas
recirculation potentiometer G212❑ If renewed, adapt en‐
gine control unit to ex‐
haust gas recirculation potentiometer - G212- , ⇒ Vehicle diagnostic tester
9 - Bolt
❑ 9 Nm
4.2
Assembly overview - intake manifold,
engine codes AXB and AXC
The intake manifold flap is closed for approx. 3 seconds when
stopping engine and then opens again. This reduces the stop jolt.
4. Intake manifold
155
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
1 - From charge air cooler
2 - Bolt
❑ 10 Nm
3 - Intake connecting pipe
❑ With mechanical ex‐
haust gas recirculation
valve and intake mani‐
fold flap
4 - Mechanical exhaust gas re‐
circulation valve
❑ Part of intake connect‐
ing pipe
5 - O-ring
❑ Renew after removing.
6 - Intake manifold
7 - Gasket
❑ Renew after removing.
8 - Connecting pipe
❑ To exhaust manifold
10 - Vacuum supply
❑ From vacuum pump
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Rep. gr.23 - Mixture preparation - injection
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156
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14 - Bolt
❑ 10 Nm
rrectness of i
t to the co
nform
spec
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wit
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13 - Bracket
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12 - Vacuum actuator
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11 - Variable intake manifold
flap changeover valve
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9 - Bolt
❑ 25 Nm
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
5
Engine control unit
⇒ “5.1 Removing and installing engine control unit”, page 157
5.1
Removing and installing engine control
unit
Note
The diesel direct injection system control unit is equipped with an
event memory. Read event memory before and after making re‐
pairs or adjustments ⇒ Vehicle diagnostic tester.
– The control unit identification must be read in order to also read
coding of the current control unit before the engine control unit
agen AG
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is removed ⇒ Vehicle
diagnostic
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–
– Unscrew securing bolts -arrows- of E box cover.
– Release and pull connectors -1- and -2- off engine control unit
in direction of arrow.
Installing
do
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– Press clip -arrow- outwards and pull control unit out in
-direction of arrow-.
rrectness of i
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nform
spec
at
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– Remove battery.
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Switchauoff
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Removing
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Installation is carried out in the reverse order; note the following:
– Insert new control unit and press downwards until clip engag‐
es.
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– Attach and lock connectors.
– Install securing bolts -arrows- of E box cover.
– Install battery.
– Check previous coding and code new control unit ⇒ Vehicle
diagnostic tester.
Specified torques
♦ Battery; Assembly overview - battery ⇒ Electrical system;
Rep. gr. 27 ; Assembly overview - battery .
♦ Removing and installing relay carrier, fuse holder, E-boxes on
left of engine compartment ⇒ Electrical system; Rep. gr. 27 ;
Removing and installing E-box on left of engine compartment
5. Engine control unit
157
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
26 –
Exhaust system
1
Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers/catalytic converters”,
page 158
⇒ “1.2 Assembly overview - silencers/particulate filter”,
page 159
⇒ “1.3 Separating exhaust pipes, silencers”, page 160
1.1
Assembly overview - silencers/catalytic converters
1 - Clip
❑ 7 Nm
2 - Gasket
❑ Renew after removing.
es, in part or in w
l purpos
hole
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10 - Separating point
❑ For repair cases
❑ During production, front and rear silencers are installed as a single component. In cases of repair, the
front and rear silencers are supplied individually and with a double clamp for connecting.
❑ Separating front and rear silencers ⇒ page 160 .
11 - Mounting
❑ With retaining ring.
❑ Renew if damaged.
158
Rep. gr.26 - Exhaust system
thi
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9 - Front and rear silencers
❑ For repairs, renew indi‐
vidually.
❑ Vehicles registered as a
commercial vehicle:
rear silencer discontin‐
ued from approx. model
year 2008.
❑ Separating front and
rear silencers
⇒ page 160 .
AG.
8 - Mounting
❑ With retaining ring.
❑ Renew if damaged.
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7 - Bolt
❑ 23 Nm
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6 - Bolt
❑ 60 Nm
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5 - Mounting
❑ With retaining ring.
❑ Renew if damaged.
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4 - Double clamp
❑ M8 = 35 Nm
❑ M10 = 52 Nm
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3 - Front exhaust pipe with cat‐
alytic converter
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
12 - Mounting for front exhaust pipe
❑ Renew if damaged.
1.2
Assembly overview - silencers/particulate filter
1 - Mounting
2 - Bolt
❑ 25 Nm
3 - Bolt
❑ 25 Nm
4 - From particulate filter
5 - Gasket
❑ Renew after removing.
6 - Connecting clamp
❑ Note installation posi‐
tion.
❑ 7 Nm
7 - Front exhaust pipe
8 - Mounting
9 - Bolt
❑ 60 Nm
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11 - Alignment dimensions in
mm
❑ -a- = approx. 5 mm.
❑ -b- = approx. 11.
❑ Exhaust system must
be cold
❑ Arrow indicates front of
vehicle.
12 - Separating point for silencer
❑ For repair cases
❑ During production, front and rear silencers are installed as a single component. In cases of repair, the
front and rear silencers are supplied individually and with a double clamp for connecting.
❑ Separating front and rear silencers ⇒ page 160 .
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15 - Clip
❑ Note installation position.
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14 - Front silencer
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13 - Alignment dimensions in mm
❑ -a- = approx. 9 mm.
❑ -b- = approx. 7.
❑ Exhaust system must be cold
❑ Arrow indicates front of vehicle.
1. Exhaust pipes, silencers
159
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
❑ M8 = 35 Nm
❑ M10 = 52 Nm
1.3
Separating exhaust pipes, silencers
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♦ Chain-type pipe cutter - VAS 6254♦ Eye protection
WARNING
Prote
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by
is not under stress and that there is sufficient clearance to the
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.
♦ Renew self-locking nuts.
Procedure
– Mark cutting location -a- = 144 mm on front silencer exhaust
pipe -1-.
– Cut through exhaust pipe at cutting location at right angle to
pipe using e.g. pneumatic sabre saw - VAS 6254- .
160
Rep. gr.26 - Exhaust system
AG.
♦ After working on the exhaust system, ensure that the system
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♦ Pneumatic sabre saw - V.A.G 1523A- rised b
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Centre repair double clamp -2- when installing.
– Align exhaust system such that it is not under tension.
Specified torques
♦ ⇒ “1.1 Assembly overview - silencers/catalytic converters”,
page 158
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♦ ⇒ “1.2 Assembly overview - silencers/particulate filter”,
page 159
1. Exhaust pipes, silencers
161
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
2
Cleansing exhaust emissions
⇒ “2.1 Assembly overview - cleansing exhaust emissions”,
page 162
⇒ “2.2 Removing and installing particulate filter”, page 163
2.1
Assembly overview - cleansing exhaust emissions
1 - Bolt
❑ 9 Nm
2 - Exhaust gas pressure sen‐
sor 1 - G4503 - Hose
4 - Control pipe
❑ 45 Nm
5 - Control pipe
❑ 45 Nm
6 - Clip
7 - Bolt
❑ 9 Nm
8 - Exhaust gas temperature
sender 3 - G495❑ 45 Nm
9 - Bolt
❑ 60 Nm
11 - To front exhaust pipe
❑ ⇒ Item 7 (page 159)
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13 - Bracket
❑ Adhere to installation
sequence:
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12 - Bolt
❑ 50 Nm + 90°
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10 - Particulate filter
❑ Removing and installing
⇒ page 163 .
♦ Tighten bolts
⇒ Item 12 (page 162) and ⇒ Item 14 (page 162) hand-tight.
♦ First tighten bolt ⇒ Item 14 (page 162) , then bolt ⇒ Item 12 (page 162) .
♦ Install particulate filter ⇒ page 163
♦ First retighten bolt ⇒ Item 14 (page 162) , then bolt ⇒ Item 12 (page 162) .
14 - Bolt
❑ 50 Nm + 90°
15 - Bolt
❑ 60 Nm
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Rep. gr.26 - Exhaust system
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162
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16 - Support
❑ Between particulate filter and cylinder block.
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
17 - Lambda probe - G39❑ Grease only the threads with high-temperature paste ; high-temperature paste ⇒ Electronic Parts Cata‐
logue (ETKA) must not get into the slots of probe body.
❑ 52 Nm
18 - Gasket
❑ Renew after removing.
❑ Note installation position.
19 - Connecting clamp
❑ Note installation position.
❑ 7 Nm
20 - From turbocharger
❑ ⇒ Item 25 (page 134)
21 - Exhaust gas temperature sender 2 - G448. Volkswagen AG
gen AG
❑ 45 Nm
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Removing and installing particulate filter
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1332-
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♦ Torque wrench - V.A.G 1331-
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23 - Bolt
❑ 9 Nm
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22 - Clip
2. Cleansing exhaust emissions
163
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Removing
Note
♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
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.
♦ Renew self-locking nuts.
WARNING
Risk of burns.
Parts of the exhaust system may be hot.
Allow exhaust system to cool before removing.
– Unplug connectors -arrow A- and Lambda probe - G39- con‐
nector -arrow B- in engine compartment.
– Release cable tie.
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The hoses remain connected to exhaust gas pressure sensor 1 G450- .
– Unclip hoses from brackets.
– Loosen connecting clamp between particulate filter and tur‐
bocharger.
– Release clamp-type clip to centre silencer.
– Remove front exhaust pipe by removing clamp -1- and un‐
screwing bolts -arrows-.
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Rep. gr.26 - Exhaust system
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164
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– Unplug connector to exhaust pressure sensor 1 - G450- -2and unscrew bolt -1-.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Unscrew bolts -arrows- and remove bracket -1-.
– Unscrew bolts -arrows- from particulate filter and remove par‐
ticulate filter.
Pay attention to lines and hoses when removing.
Installing
Installation is carried out in the reverse order; note the following:
Caution
Ensure that the particulate filter is not installed under stress.
The particulate filter could be damaged.
Follow the installation sequence.
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– Place particulate filter with newaugasket
s
and place it on the bracket ⇒ sItem
13 (page 162) .
– Tighten clamp between turbocharger and particulate filter.
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– Tighten securing bolts -arrows- of particulate filter.
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2. Cleansing exhaust emissions
165
AG.
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Fit bolt -1- of bracket on cylinder block.
– Tighten bolts -arrows-, first on particulate filter and then on
cylinder block.
– Install front exhaust pipe.
– Tighten bolts -arrows-.
– Tighten clamp -1-.
– Screw on exhaust gas pressure sensor 1 - G450- and connect
connector.
– Clip hoses onto bulkhead.
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– Fit connectors -A- and -B-. Secure wiring harness with
ties at positions marked.
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Specified torques
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If a new particulate filter was installed, an “ash mass comparison”
must be carried out ⇒ Vehicle diagnostic tester.
♦ ⇒ “2.1 Assembly overview - cleansing exhaust emissions”,
page 162
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Rep. gr.26 - Exhaust system
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166
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♦ ⇒ “1.2 Assembly overview - silencers/particulate filter”,
page 159
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
3
Exhaust gas recirculation
⇒ “3.1 Assembly overview - exhaust gas recirculation, engine co‐
des AXB and AXC”, page 167
⇒ “3.2 Assembly overview - exhaust gas recirculation, engine co‐
des BRR and BRS”, page 168
3.1
Assembly overview - exhaust gas recir‐
culation, engine codes AXB and AXC
Note
♦ The exhaust gas recirculation system is activated from the
diesel direct injection control unit - J248- to the exhaust gas
recirculation valve - N18- .
♦ The tapered plunger in the mechanical exhaust gas recircula‐
tion valve varies the opening cross-section according to the
opening lift.
♦ Pulsed control enables every conceivable valve position.
♦ Renew self-locking nuts.
1 - From charge air cooler
2 - Bolt
❑ 10 Nm
3 - Intake connecting pipe
❑ With mechanical ex‐
haust gas recirculation
valve and intake mani‐
fold flap
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4 - Mechanical exhaust gas re‐
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❑ Part of intake connect‐
ing pipe
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5 - O-ring
❑ Renew after removing.
6 - Intake manifold
7 - Exhaust manifold
8 - Gasket
❑ Renew after removing.
9 - Nut
❑ 25 Nm
10 - Connecting pipe
11 - Vacuum actuator
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3. Exhaust gas recirculation
167
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Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
AG. Volkswagen AG d
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Note
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Assembly overview - exhaust gas recir‐by Volksw
ed
ris
culation, engine codes BRR and BRS
o
h
t
♦ The exhaust gas recirculation system is activated by the en‐
6 - Bolt
❑ 9 Nm
7 - From exhaust manifold
❑ ⇒ Item 3 (page 135)
8 - Nut
❑ 20 Nm
9 - Connecting pipe
10 - Coolant hose
❑ Coolant hose schematic
diagram ⇒ page 107 .
168
Rep. gr.26 - Exhaust system
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5 - Exhaust gas recirculation
cooler
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4 - Bolt
❑ 20 Nm
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3 - Connecting pipe
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2 - Gasket
❑ Renew after removing.
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1 - To intake manifold.
❑ ⇒ page 155
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gine control unit - J623- via the exhaust gas recirculation
potentiometer - G212- .
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3.2
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
28 –
Glow plug system
1
Glow plug system
⇒ “1.1 Checking metal glow plugs”, page 169
⇒ “1.2 Removing and installing engine speed sender G28 ”, page
170
⇒ “1.3 Removing and installing Hall sender G40 ”, page 171
1.1
Checking metal glow plugs
Special tools and workshop equipment required
♦ Auxiliary measuring set - V.A.G 1594C-
♦ Jointed wrench 10 mm - 3220-
es, in part or in w
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♦ Voltage tester - V.A.G 1527B-
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169
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
Distinguishing characteristics of glow plugs:
A - Ceramic glow plug: white colour code -arrow- with shoulder
on the tip (close-up)
B - Metal glow plug, green colour code -arrowNote
Check ceramic glow plugs only using ⇒ Vehicle diagnostic tester.
Test prerequisites
•
Battery voltage at least 11.5 V
•
Ignition switched off
•
Fuse for glow plugs OK.
Test procedure
– 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., diode
does not light up: renew glow plug.
– Use U/J extension and socket, 10 mm - 3220- to remove and
install glow plugs.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
es, in part or in w
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hole
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Removing and installing engine speed sender - G28- , engine co‐
des AXB and AXC ⇒ Item 8 (page 16) .
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Removing and installing engine speed
sender - G28pe
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Special tools and workshop equipment required
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Rep. gr.28 - Glow plug system
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– Remove any noise insulation ⇒ General body repairs, exteri‐
or; Rep. gr. 50 ; Body, front; Noise insulation .
do
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Removing
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♦ Torque wrench - V.A.G 1331-
Transporter 2004 ➤
4-cylinder diesel engine - Edition 04.2013
– Remove engine oil cooler ⇒ page 100 .
– Pull connector off engine speed sender - G28- .
– Unscrew securing bolt -arrow- and pull out engine speed
sender - G28- .
Installing
Installation is carried out in the reverse order; note the following:
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
26
♦ ⇒ “2.1 Assembly overview - oil filter housing, oil pressure
switch”, page 100
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
1.3
Removing and installing Hall sender G40-
Removing
– Remove pressure pipe ⇒ page 139 .
– Remove toothed belt guard upper part ⇒ page 64 .
– Screw off Hall sender - G40- -arrow-.
Note
Item -1- can be disregarded.
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– Unclip and remove wiring -arrows- from guide and remove
cover cap -2-.
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– Remove Hall sender - G40- from cylinder head, disconnect
connector, pull connector out of holder and remove Hall send‐
er - G40- .
Installation is carried out in the reverse order; note the following:
– Seal repair aperture in toothed belt guard with rubber plugs as
specified in ⇒ Electronic Parts Catalogue (ETKA) .
– Install pressure pipe ⇒ page 139 .
– Install toothed belt guard upper part ⇒ page 64 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 44
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