Name: 4-cyl. common rail (2.0 l, 4V, turbocharger, transverse engine)
Brand: Volkswagen
SKU: CDG5c39d3f10b67
Price: 35.57 EUR
Availability: InStock

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Repair manual Crafter / TGE 4-cyl. common rail PDF download has the following content:

Chapter overview

Technical data
1
1 Safety information
1
1.1 Safety regulations for working on fuel supply
1
1.2 Safety measures when working on vehicles with start/stop system
2
1.4 Safety precautions when working on the cooling system
2
1.5 Safety precautions when working on the SCR system
2
1.6 Safety precautions when working on ignition system
3
1.7 Safety precautions when working on exhaust system
3
2 Identification
4
2.1 Engine number/engine data
4
3 Repair notes
5
3.1 Rules for cleanliness
5
3.2 General information
5
3.3 Foreign objects in engine
6
3.4 Contact corrosion
6
3.5 Routing and attachment of lines
6
3.6 Checking vacuum system
6
Removing and installing engine
8
1 Removing and installing motor
8
1.1 Removing motor
8
1.2 Separating engine and gearbox
17
1.3 Securing engine on engine and gearbox support
19
1.4 Installing engine
20
2 Assembly mountings
24
2.1 Assembly overview - assembly mountings
24
2.2 Removing and installing engine mounting
25
2.3 Removing and installing gearbox mountings
27
2.4 Removing and installing pendulum support
29
2.5 Supporting engine in installation position
30
Crankshaft group
36
1 Cylinder block (pulley end)
36
1.1 Assembly overview - cylinder block (pulley end)
36
1.2 Assembly overview - sealing flange, belt pulley end
39
1.3 Removing and installing poly-V belt
40
1.4 Removing and installing tensioner for poly V-belt
43
1.5 Removing and installing vibration damper
43
1.6 Removing and installing bracket for ancillaries
45
1.7 Removing and installing engine support
47
1.8 Removing and installing sealing flange on pulley end
48
1.9 Removing and installing cover for poly V-belt
51
2 Cylinder block, gearbox end
52
2.1 Assembly overview - cylinder block, gearbox end
52
2.2 Assembly overview - drive plate
54
2.3 Removing and installing drive plate
55
2.4 Removing and installing flywheel
56
2.5 Removing and installing sealing flange on gearbox side
58
3 Crankshaft
68
3.1 Assembly overview - crankshaft
68
3.2 Crankshaft dimensions
70
3.3 Renewing needle bearing in crankshaft
70
3.4 Measuring axial clearance of crankshaft
72
3.5 Measuring radial clearance of crankshaft
73
4 Auxiliary drive
74
4.1 Assembly overview - ancillary drive
74
4.2 Removing and installing 2nd alternator
76
4.3 Removing and installing 2nd air conditioner compressor
77
4.4 Removing and installing bracket for auxiliary drive
81
5 Pistons and conrods
84
5.1 Assembly overview - pistons and conrods
84
5.2 Removing and installing pistons
86
5.3 Measuring piston projection at TDC
88
5.4 Checking pistons and cylinder bores
90
5.5 Separating new conrod
93
5.6 Checking radial clearance of conrods
93
5.7 Removing and installing oil spray jets
94
Cylinder head, valve gear
96
1 Cylinder head
96
1.1 Assembly overview - cylinder head
96
1.2 Assembly overview - camshaft housing
99
1.3 Assembly overview - cylinder head cover
101
1.4 Removing and installing cylinder head
103
1.5 Removing and installing cylinder head cover
111
1.6 Removing and installing injector seals
113
1.7 Removing and installing camshaft housing
114
1.8 Checking compression
119
2 Toothed belt drive
121
2.1 Assembly overview - toothed belt cover
121
2.2 Assembly overview - toothed belt
121
2.3 Removing and installing toothed belt guard
124
2.4 Removing and installing toothed belt
128
2.5 Removing toothed belt from camshaft
144
3 Valve gear
152
3.1 Assembly overview - valve gear
152
3.2 Measuring axial play of camshaft
154
3.3 Removing and installing camshaft oil seal
155
3.4 Checking hydraulic compensation elements
157
3.5 Removing and installing valve stem seals
157
3.6 Removing and installing toothed belt pulley
170
4 Inlet and exhaust valves
172
4.1 Checking valve guides
172
4.2 Checking valves
173
4.3 Valve dimensions
173
Lubrication
174
1 Sump, oil pump
174
1.1 Assembly overview - sump/oil pump
174
1.2 Engine oil:
176
1.3 Removing and installing sump
176
1.4 Removing and installing oil pump
180
1.5 Removing and installing oil level and oil temperature sender G266
181
1.6 Removing and installing toothed belt for oil pump
183
2 Engine oil cooler
184
3 Oil filter, oil pressure switch
185
3.1 Assembly overview - oil filter housing, oil pressure switch
185
3.2 Removing and installing oil pressure switch F1
187
3.3 Removing and installing oil pressure switch for reduced oil pressure F378
188
3.4 Checking oil pressure
190
3.5 Removing and installing oil filter housing
190
3.6 Removing and installing oil pressure regulating valve N428
193
3.7 Measuring oil consumption
194
4 Oil circuit
195
4.1 Assembly overview - oil circuit
195
4.2 Removing and installing oil supply line
197
4.3 Removing and installing oil return line for turbocharger
200
Cooling
205
1 Cooling system/coolant
205
1.1 Assembly overview – coolant expansion tank
205
1.2 Connection diagram - coolant hoses
206
1.3 Checking cooling system for leaks
214
1.4 Draining and adding coolant
216
1.5 Removing and installing coolant expansion tank
234
2 Coolant pump, regulation of cooling system
237
2.1 Assembly overview - coolant pump, thermostat
237
2.2 Assembly overview - electric coolant pump
239
2.3 Assembly overview - coolant temperature sender
240
2.4 Removing and installing pump for exhaust gas recirculation cooler V400
240
2.5 Removing and installing charge air cooling pump V188
242
2.6 Removing and installing auxiliary pump for heating V488
244
2.7 Removing and installing coolant pump
245
2.8 Removing and installing thermostat
246
2.9 Checking thermostat
248
2.10 Removing and installing coolant valve for cylinder head N489
248
2.11 Removing and installing coolant temperature sender G62
250
2.12 Removing and installing radiator outlet coolant temperature sender G83
251
2.13 Removing and installing coolant temperature sender 3 G812
253
2.14 Removing and installing shut-off valve
256
3 Coolant pipes
259
3.1 Assembly overview - coolant pipes
259
3.2 Removing and installing coolant pipes
261
4 Radiator, radiator fan
276
4.1 Assembly overview - radiator/radiator fan
276
4.2 Assembly overview - radiator cowl and radiator fan
277
4.3 Removing and installing radiator
278
4.4 Removing and installing radiator cowl with radiator fan
282
4.5 Removing and installing radiator fan V7
283
4.6 Removing and installing auxiliary radiator
284
4.7 Removing and installing radiator blind control motors V544/V550
286
Turbocharging/supercharging
289
1 Turbocharger
289
1.1 Assembly overview - turbocharger
289
1.2 Removing and installing turbocharger
295
1.3 Renewing vacuum unit for turbocharger
304
1.4 Removing and installing compressor housing and turbine housing
317
1.5 Removing and installing upper connecting pipe
319
1.6 Removing and installing lower connecting pipe
320
2 Charge air system
323
2.1 Assembly overview - charge air system
323
2.2 Removing and installing charge air cooler
325
2.3 Removing and installing charge pressure sender 2 G447
328
2.4 Checking charge air system for leaks
329
2.5 Detaching and securing charge air cooler
331
2.6 Removing and installing bracket for charge air cooler
333
2.7 Checking charge air cooler for leaks
334
Mixture preparation - injection
337
1 Injection system
337
1.1 Filling/bleeding fuel system
337
1.2 Checking fuel system for leaks
338
2 Vacuum system
339
2.1 Connection diagram - vacuum system
339
2.2 Assembly overview - vacuum system
342
2.3 Assembly overview - vacuum pipes
343
2.4 Checking vacuum system
344
2.5 Removing and installing solenoid valves N75/N274/N529/N316
345
2.6 Removing and installing vacuum pipes
346
3 Injectors/high-pressure accumulator (rail)
348
3.1 Assembly overview - injectors
348
3.2 Assembly overview - fuel rail
350
3.3 Adapting correction values for injectors
351
3.4 Testing injectors
352
3.5 Testing jammed-open injectors
353
3.6 Checking return flow rate of injectors with engine running
355
3.7 Checking return flow rate of injectors at starter speed
356
3.8 Removing and installing injectors
359
3.9 Removing and installing high-pressure lines
362
3.10 Removing and installing fuel rail
368
4 Air filter
371
4.1 Assembly overview - air filter housing
371
4.2 Removing and installing air filter housing
371
5 Intake manifold
373
5.1 Assembly overview - intake manifold
373
5.2 Removing and installing intake manifold
375
5.3 Removing and installing throttle valve module GX3
378
5.4 Removing and installing vacuum unit for intake manifold
379
6 Senders and sensors
381
6.1 Removing and installing fuel pressure regulating valve N276
381
6.2 Checking fuel pressure regulating valve N276
383
6.3 Removing and installing fuel pressure sender G247
384
6.4 Removing and installing air mass meter G70
386
6.5 Removing and installing pressure differential sender G505
387
6.8 Removing and installing fuel temperature sender G81
390
6.9 Removing and installing control unit for NOx sender J583/NOx sender G295
392
6.10 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
393
6.13 Removing and installing intake manifold sender GX9
398
7 Engine control unit
399
7.1 Removing and installing engine control unit J623
399
8 High-pressure pump
401
8.1 Assembly overview - high-pressure pump
401
8.2 Removing and installing high-pressure pump
402
8.3 Checking high-pressure pump
407
9 Lambda probe
410
9.1 Assembly overview - Lambda probe
410
9.2 Removing and installing Lambda probe 1 before catalytic converter GX10
411
Exhaust system
413
1 Exhaust pipes and silencers
413
1.1 Assembly overview - silencers
413
1.2 Removing and installing front silencer
414
1.3 Aligning exhaust system free of stress
416
1.4 Checking exhaust system for leaks
417
1.5 Installation position of clamp
417
1.6 Removing and installing exhaust tailpipe
417
2 Emission control
419
2.1 Assembly overview - emission control
419
2.2 Removing and installing catalytic converter
421
2.3 Removing and installing particulate filter
423
3 SCR system (selective catalytic reduction)
427
3.1 Assembly overview - tank for reducing agent
427
3.2 Assembly overview - delivery module for reducing agent
428
3.3 Removing and installing reducing agent tank VX85
429
3.4 Removing and installing delivery unit for reducing agent metering system GX19
433
3.5 Removing and installing injector for reduction agent N474
435
3.6 Removing and installing control unit for reducing-agent heater J891
438
3.7 Draining reducing agent tank VX85
439
3.8 Removing and installing filler pipe for reducing agent tank VX85
441
3.9 Disconnecting reducing agent supply line
444
3.10 SCR - resetting learnt values
446
4 Exhaust gas temperature regulation
447
4.1 Assembly overview - exhaust gas temperature regulation
447
4.2 Removing and installing exhaust gas temperature sender 1 G235
447
4.3 Removing and installing exhaust gas temperature sender 2 G448
449
4.4 Removing and installing exhaust gas temperature sender 3 G495
451
5 Exhaust gas recirculation
454
5.1 Assembly overview - exhaust gas recirculation
454
5.2 Removing and installing exhaust gas recirculation cooler
456
5.3 Removing and installing exhaust gas recirculation pipes
460
5.4 Removing and installing temperature sensor 2 for exhaust gas recirculation G690
462
5.5 Checking exhaust gas recirculation cooler for leaks
463
5.6 Removing and installing temperature sensor 3 for exhaust gas recirculation G949
466
5.7 Removing and installing bracket for exhaust gas recirculation cooler
467
Glow plug system
475
1 Glow plug system
475
1.1 Assembly overview - glow plug system
475
1.2 Removing and installing glow plug
476
1.3 Checking glow plug
480
1.4 Removing and installing automatic glow period control unit J179
480
1.5 Removing and installing knock sensor 1 G61
481
1.6 Removing and installing knock sensor 2 G66
483
1.7 Removing and installing Hall sender G40
484
1.8 Removing and installing engine speed sender G28
484

Manufacturer's designation	4-cyl. common rail (2.0 l, 4V, turbocharger, transverse engine)
Manufacturer	Volkswagen
Suitable for	Crafter () / TGE (2017 > )
Suitable car types	SY, UZ, UY, SCB, SCC
Engine code	DAVA, DAUB
Category	Reparaturanleitung

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