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  • Examplepage for repair manual 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 2 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, 4V, turbocharger)

4-cylinder common rail engine (2.0 l, 4V, turbocharger)

For Transporter

Original Volkswagen repair manual


45,87 €7% VAT incl.

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  • English

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Language: English

Digital PDF file

79.456 KB

725 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual Transporter 4-cylinder common rail engine 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 a 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
    3
  • 1.6 Safety precautions when working on ignition system
    3
  • 1.7 Safety precautions when working on exhaust system
    4
  • 2 Identification
    5
  • 2.1 Engine number/engine data
    5
  • 3 Repair instructions
    7
  • 3.1 Rules for cleanliness
    7
  • 3.2 General notes
    7
  • 3.3 General repair instructions
    8
  • 3.4 Foreign objects in engine
    8
  • 3.5 Contact corrosion
    8
  • 3.6 Routing and attachment of lines
    9
  • 3.7 Fitting radiator and condensers
    9
  • 3.8 Checking vacuum system
    9
  • Removing and installing engine
    16
  • 1 Removing and installing engine
    16
  • 1.1 Removing engine
    16
  • 1.2 Separating engine and gearbox
    26
  • 1.3 Securing engine on engine and gearbox support
    28
  • 1.4 Installing engine
    30
  • 2 Assembly mountings
    34
  • 2.1 Assembly overview - assembly mountings
    34
  • 2.2 Removing and installing engine mounting
    44
  • 2.3 Removing and installing engine mounting
    50
  • 2.4 Removing and installing gearbox mounting
    51
  • 2.5 Removing and installing damper weight
    53
  • 2.6 Supporting engine in installation position
    53
  • 3 Engine cover panel
    58
  • 3.1 Assembly overview – engine compartment cover
    58
  • 3.2 Removing and installing engine compartment cover
    58
  • Crankshaft group
    60
  • 1 Cylinder block (pulley end)
    60
  • 1.1 Assembly overview - cylinder block (pulley end)
    60
  • 1.2 Assembly overview - sealing flange, belt pulley end
    65
  • 1.3 Removing and installing poly-V belt
    66
  • 1.4 Removing and installing tensioner for poly V-belt
    70
  • 1.5 Removing and installing vibration damper
    71
  • 1.6 Removing and installing bracket for ancillaries
    75
  • 1.7 Removing and installing engine support
    79
  • 1.8 Removing and installing sealing flange on pulley end
    89
  • 1.9 Renewing caps in cylinder block (pulley end)
    91
  • 2 Cylinder block, gearbox end
    93
  • 2.1 Assembly overview - cylinder block, gearbox end
    93
  • 2.2 Removing and installing flywheel
    95
  • 2.3 Removing and installing sealing flange on gearbox side
    96
  • 2.4 Renewing caps in cylinder block (gearbox end)
    116
  • 3 Crankshaft
    118
  • 3.1 Assembly overview - crankshaft
    118
  • 3.2 Crankshaft dimensions
    120
  • 3.3 Renewing needle bearing in crankshaft
    120
  • 3.4 Measuring axial clearance of crankshaft
    122
  • 3.5 Measuring radial clearance of crankshaft
    123
  • 4 Pistons and conrods
    124
  • 4.1 Assembly overview - pistons and conrods
    124
  • 4.2 Removing and installing pistons
    127
  • 4.3 Measuring piston projection at TDC
    128
  • 4.4 Checking pistons and cylinder bores
    130
  • 4.5 Separating new conrod
    133
  • 4.6 Checking radial clearance of conrods
    133
  • 4.7 Removing and installing oil spray jets
    134
  • Cylinder head, valve gear
    136
  • 1 Cylinder head
    136
  • 1.1 Assembly overview - cylinder head
    136
  • 1.2 Assembly overview - camshaft housing
    139
  • 1.3 Assembly overview - cylinder head cover
    141
  • 1.4 Removing and installing cylinder head
    144
  • 1.5 Removing and installing cylinder head cover
    152
  • 1.6 Removing and installing injector seals
    154
  • 1.7 Removing and installing camshaft housing
    155
  • 1.8 Checking compression
    161
  • 2 Toothed belt drive
    163
  • 2.1 Assembly overview - toothed belt cover
    163
  • 2.2 Assembly overview - toothed belt
    163
  • 2.3 Removing and installing toothed belt guard
    165
  • 2.4 Removing and installing toothed belt
    170
  • 2.5 Removing toothed belt from camshaft
    185
  • 3 Valve gear
    192
  • 3.1 Assembly overview - valve gear
    192
  • 3.2 Measuring axial play of camshaft
    194
  • 3.3 Removing and installing camshaft oil seal
    195
  • 3.4 Checking hydraulic compensation elements
    197
  • 3.5 Removing and installing valve stem seals
    198
  • 4 Inlet and exhaust valves
    215
  • 4.1 Checking valve guides
    215
  • 4.2 Checking valves
    216
  • 4.3 Valve dimensions
    216
  • Lubrication
    218
  • 1 Sump, oil pump
    218
  • 1.1 Assembly overview - sump/oil pump
    218
  • 1.2 Assembly overview - oil pump drive pulley
    223
  • 1.3 Engine oil:
    224
  • 1.4 Removing and installing oil sump
    224
  • 1.5 Removing and installing oil pump
    229
  • 1.6 Removing and installing oil level and oil temperature sender G266
    231
  • 1.7 Removing and installing sump trim
    231
  • 1.8 Removing and installing oil pump drive pulley
    232
  • 2 Engine oil cooler
    237
  • 3 Oil filter, oil pressure switch
    238
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    238
  • 3.2 Removing and installing oil pressure switch F1
    240
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    242
  • 3.4 Checking oil pressure
    243
  • 3.5 Removing and installing oil filter housing
    243
  • 3.6 Removing and installing oil pressure regulating valve N428
    246
  • 4 Oil circuit
    248
  • 4.1 Assembly overview - oil circuit
    248
  • 4.2 Removing and installing oil supply line
    251
  • 4.3 Removing and installing oil return line for turbocharger
    255
  • Cooling
    259
  • 1 Cooling system/coolant
    259
  • 1.1 Connection diagram - coolant hoses
    259
  • 1.2 Draining and adding coolant
    283
  • 1.3 Checking coolant level and topping up
    292
  • 1.4 Checking cooling system for leaks
    293
  • 1.5 Removing and installing coolant expansion tank
    296
  • 1.6 Assembly overview – coolant expansion tank
    300
  • 2 Coolant pump, regulation of cooling system
    301
  • 2.1 Assembly overview - coolant pump, thermostat
    301
  • 2.2 Assembly overview - electric coolant pump
    303
  • 2.3 Assembly overview - coolant temperature sender
    310
  • 2.4 Assembly overview – coolant valves, 3/2-way valve
    313
  • 2.5 Removing and installing electric coolant pump
    314
  • 2.6 Removing and installing coolant pump
    320
  • 2.7 Removing and installing thermostat
    321
  • 2.8 Checking thermostat
    324
  • 2.9 Removing and installing coolant valve for cylinder head N489
    324
  • 2.10 Removing and installing coolant temperature sender G62
    325
  • 2.11 Removing and installing radiator outlet coolant temperature sender G83
    327
  • 2.12 Removing and installing coolant temperature sender 3 G812
    329
  • 2.13 Removing and installing 3/2-way valve
    332
  • 2.14 Removing and installing front shut-off flap
    336
  • 3 Coolant pipes
    338
  • 3.1 Assembly overview - coolant pipes
    338
  • 3.2 Removing and installing coolant pipes
    345
  • 4 Radiator, radiator fan
    347
  • 4.1 Assembly overview - radiator/radiator fan
    347
  • 4.2 Assembly overview – radiator cowl and radiator fan
    351
  • 4.3 Removing and installing radiator
    351
  • 4.4 Removing and installing radiator cowl with radiator fan
    366
  • 4.5 Removing and installing radiator fan V7
    367
  • Turbocharging/supercharging
    369
  • 1 Turbocharger
    369
  • 1.1 Assembly overview - turbocharger
    369
  • 1.2 Removing and installing turbocharger
    378
  • 1.3 Checking vacuum unit for turbocharger, biturbo
    389
  • 1.4 Removing and installing upper connecting pipes
    404
  • 1.5 Removing and installing compressor housing and turbine housing, biturbo
    410
  • 2 Charge air system
    412
  • 2.1 Assembly overview - charge air system
    412
  • 2.2 Removing and installing charge air cooler
    418
  • 2.3 Removing and installing charge pressure sender G31
    427
  • 2.4 Removing and installing charge pressure sender 2 G447
    428
  • 2.5 Checking charge air system for leaks
    429
  • 2.6 Detaching and securing charge air cooler
    431
  • 2.7 Removing and installing bracket for charge air cooler
    438
  • 2.8 Checking charge air cooler for leaks
    442
  • Mixture preparation - injection
    446
  • 1 Injection system
    446
  • 1.1 Overview of fitting locations - injection system
    446
  • 1.2 Filling/bleeding fuel system
    461
  • 1.3 Checking fuel system for leaks
    462
  • 2 Vacuum system
    463
  • 2.1 Connection diagram – vacuum system
    463
  • 2.2 Assembly overview – vacuum system
    466
  • 2.3 Assembly overview – valves for vacuum system
    471
  • 2.4 Removing and installing solenoid valves N75/N274/N529
    475
  • 3 Injectors/high-pressure accumulator (rail)
    477
  • 3.1 Assembly overview - injectors
    477
  • 3.2 Assembly overview - fuel rail
    479
  • 3.3 Adapting correction values for injectors
    481
  • 3.4 Testing injectors
    482
  • 3.5 Testing jammed-open injectors
    482
  • 3.6 Checking return flow rate of injectors with engine running
    484
  • 3.7 Checking return flow rate of injectors at starter speed
    486
  • 3.8 Removing and installing injectors
    489
  • 3.9 Removing and installing high-pressure lines
    493
  • 3.10 Removing and installing fuel rail
    498
  • 4 Air filter
    500
  • 4.1 Assembly overview - air filter housing
    500
  • 4.2 Removing and installing air filter housing
    504
  • 5 Intake manifold
    507
  • 5.1 Assembly overview – intake manifold
    507
  • 5.2 Removing and installing intake manifold
    511
  • 5.3 Removing and installing throttle valve module GX3
    516
  • 5.4 Removing and installing intake manifold flap valve N316
    518
  • 5.5 Removing and installing vacuum unit for intake manifold
    520
  • 6 Senders and sensors
    522
  • 6.1 Removing and installing fuel pressure regulating valve N276
    522
  • 6.2 Checking fuel pressure regulating valve N276
    525
  • 6.3 Removing and installing fuel pressure sender G247
    526
  • 6.4 Removing and installing air mass meter G70
    528
  • 6.5 Removing and installing pressure differential sender G505
    530
  • 6.8 Removing and installing fuel temperature sender G81
    534
  • 6.10 Removing and installing intake manifold sender GX9
    540
  • 6.12 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
    543
  • 6.13 Removing and installing control unit for NOx sender J583/NOx sender G295
    547
  • 6.14 Overview of fitting locations - exhaust gas sensors
    554
  • 7 Engine control unit
    557
  • 7.1 Removing and installing engine control unit J623
    557
  • 8 High-pressure pump
    559
  • 8.1 Assembly overview - high-pressure pump
    559
  • 8.2 Removing and installing high-pressure pump
    562
  • 8.3 Checking high-pressure pump
    566
  • 9 Lambda probe
    569
  • 9.1 Assembly overview - Lambda probe
    569
  • 9.2 Removing and installing Lambda probe 1 before catalytic converter GX10
    571
  • Exhaust system
    576
  • 1 Exhaust pipes and silencers
    576
  • 1.1 Assembly overview – silencers
    576
  • 1.2 Separating exhaust pipes from silencers
    578
  • 1.3 Removing and installing front silencer
    580
  • 1.4 Removing and installing rear silencer
    581
  • 1.5 Aligning exhaust system free of stress
    583
  • 1.6 Checking exhaust system for leaks
    584
  • 1.7 Installation position of clamp
    585
  • 2 Emission control
    586
  • 2.1 Assembly overview – emission control
    586
  • 2.2 Removing and installing catalytic converter
    607
  • 2.3 Removing and installing particulate filter
    616
  • 3 SCR system (selective catalytic reduction)
    624
  • 3.1 Assembly overview – reducing agent tank
    624
  • 3.2 Assembly overview - delivery module for reducing agent
    625
  • 3.3 Assembly overview – filler tube for reducing agent tank
    626
  • 3.4 Assembly overview - injector for reducing agent N474
    627
  • 3.5 Removing and installing reducing agent tank VX85
    628
  • 3.6 Removing and installing reducing agent supply line
    631
  • 3.7 Removing and installing delivery unit for reducing agent metering system GX19
    634
  • 3.8 Removing and installing injector for reduction agent N474
    637
  • 3.9 Removing and installing control unit for reducing-agent heater J891
    640
  • 3.10 Draining reducing agent tank VX85
    640
  • 3.11 Removing and installing filler pipe for tank for reducing agent
    643
  • 4 Exhaust gas temperature regulation
    645
  • 4.1 Assembly overview – exhaust gas temperature regulation
    645
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    648
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    657
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    661
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    666
  • 5 Exhaust gas recirculation
    671
  • 5.1 Assembly overview – exhaust gas recirculation
    671
  • 5.2 Removing and installing exhaust gas recirculation cooler
    673
  • 5.3 Removing and installing exhaust gas recirculation pipes
    686
  • 5.4 Removing and installing temperature sensor 2 for exhaust gas recirculation G690
    690
  • 5.5 Checking exhaust gas recirculation cooler for leaks
    691
  • 5.6 Removing and installing temperature sensor 3 for exhaust gas recirculation G949
    695
  • Glow plug system
    704
  • 1 Glow plug system
    704
  • 1.1 Assembly overview - glow plug system
    704
  • 1.2 Removing and installing glow plug
    705
  • 1.3 Checking glow plug
    710
  • 1.4 Removing and installing automatic glow period control unit J179
    710
  • 1.5 Removing and installing knock sensor 1 G61
    710
  • 1.6 Removing and installing knock sensor 2 G66
    712
  • 1.7 Removing and installing Hall sender G40
    713
  • 1.8 Removing and installing engine speed sender G28
    714
Manufacturer's designation 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
Manufacturer Volkswagen
Suitable for Transporter (2016) / Transporter (2020 >)
Suitable car types SF, SH, SJ
Engine code CXFA, CXGA, CXGB, CXHA, CXGC, CXHB, CXEC, CXGD, CXGE, CXHC
Category Reparaturanleitung

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