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  • Examplepage for repair manual 4-cylinder diesel engine
  • Examplepage for repair manual 2 4-cylinder diesel engine
  • Examplepage for repair manual 3 4-cylinder diesel engine

4-cylinder diesel engine

For California / Multivan / Transporter / Transporter/Kombi LR

Original Volkswagen repair manual


14,51 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

5.374 KB

171 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, 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 and Intake manifold. Show more
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Repair manual 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Engine number/engine data
    1
  • 1.1 Engine number/engine data
    1
  • 2 Safety information
    2
  • 2.1 Safety precautions when working on cooling system
    2
  • 2.2 Safety measures when working on fuel supply
    3
  • 2.3 Safety precautions when working on injection system
    4
  • 3 Repair notes
    5
  • 3.1 Rules for cleanliness when working on fuel supply system/injection system
    5
  • 3.2 Rules for cleanliness during work on fuel system
    5
  • Removing and installing engine
    6
  • 1 Removing and installing engine
    6
  • 1.1 Removing engine
    6
  • 1.2 Securing engine to assembly stand
    12
  • 1.3 Installing engine
    12
  • 2 Assembly mountings
    15
  • 2.1 Assembly overview - assembly mountings
    15
  • Crankshaft group
    16
  • 1 Cylinder block (pulley end)
    16
  • 1.1 Assembly overview - poly V-belt drive
    16
  • 1.2 Assembly overview - crankcase
    17
  • 1.3 Removing and installing poly-V belt
    18
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    20
  • 1.5 Removing and installing sealing flange on pulley end
    22
  • 2 Cylinder block, gearbox end
    26
  • 2.1 Assembly overview - cylinder block, gearbox end
    26
  • 2.2 Removing and installing sealing flange on gearbox side
    28
  • 3 Crankshaft
    37
  • 3.1 Assembly overview - crankshaft
    37
  • 3.2 Removing and installing sender wheel
    38
  • 3.3 Crankshaft dimensions
    39
  • 4 Pistons and conrods
    40
  • 4.1 Assembly overview - pistons and conrods
    40
  • 4.2 Measuring piston projection at TDC
    42
  • 4.3 Checking pistons and cylinder bores
    43
  • 4.4 Piston and cylinder dimensions
    44
  • Cylinder head, valve gear
    45
  • 1 Cylinder head
    45
  • 1.1 Assembly overview - cylinder head
    45
  • 1.2 Removing and installing cylinder head
    48
  • 1.3 Removing and installing cylinder head cover
    56
  • 1.4 Checking compression
    58
  • 2 Toothed belt drive
    61
  • 2.1 Assembly overview - toothed belt drive
    61
  • 2.2 Removing and installing toothed belt, vehicles ► 12.05
    62
  • 2.3 Removing and installing toothed belt, vehicles 01.06 ►
    70
  • 3 Valve gear
    79
  • 3.1 Assembly overview - valve gear
    79
  • 3.2 Measuring axial clearance of camshaft
    80
  • 3.3 Removing and installing camshaft oil seal
    81
  • 3.4 Removing and installing camshaft
    83
  • 3.5 Removing and installing valve stem seal
    88
  • 4 Inlet and exhaust valves
    91
  • 4.1 Checking valve guides
    91
  • Lubrication
    92
  • 1 Sump, oil pump
    92
  • 1.1 Assembly overview - sump/oil pump
    92
  • 1.2 Removing and installing sump
    93
  • 1.3 Engine oil:
    96
  • 2 Oil filter, oil pressure switch
    97
  • 2.1 Assembly overview - oil filter housing, oil pressure switch
    97
  • 2.2 Checking oil pressure and oil pressure switch
    98
  • 2.3 Measuring oil consumption
    99
  • 3 Oil circuit
    100
  • 3.1 Assembly overview - oil supply line
    100
  • 3.2 Removing and installing oil supply line
    100
  • Cooling
    103
  • 1 Cooling system/coolant
    103
  • 1.1 Coolant hose schematic diagram - engine codes AXB and AXC
    103
  • 1.2 Coolant hose schematic diagram - engine codes BRR and BRS
    104
  • 1.3 Draining and adding coolant
    105
  • 1.4 Checking cooling system for leaks
    112
  • 2 Coolant pump, regulation of cooling system
    114
  • 2.1 Assembly overview - coolant pump, thermostat
    114
  • 2.2 Removing and installing coolant pump
    115
  • 2.3 Removing and installing thermostat
    116
  • 3 Radiator, radiator fan
    119
  • 3.1 Assembly overview - radiator/radiator fan
    119
  • 3.2 Removing and installing radiator
    120
  • Turbocharging/supercharging
    123
  • 1 Turbocharger
    123
  • 1.1 Assembly overview - turbocharger, engine codes AXB and AXC
    123
  • 1.2 Assembly overview - turbocharger, engine codes BRR and BRS
    125
  • 1.3 Removing and installing turbocharger
    127
  • 2 Charge air system
    129
  • 2.1 Assembly overview - charge air system
    129
  • 2.2 Assembly overview - charge-air hose connections
    130
  • 2.3 Checking charge air system for leaks
    131
  • Mixture preparation - injection
    133
  • 1 Injectors
    133
  • 1.1 Assembly overview - injectors
    133
  • 1.2 Removing and installing O-rings for unit injector
    134
  • 1.3 Removing and installing injectors
    135
  • 1.4 Removing and installing prewiring for unit injectors
    138
  • 2 Vacuum system
    142
  • 2.1 Vacuum system schematic diagram - engine codes AXB and AXC
    142
  • 2.2 Vacuum system schematic diagram - engine codes BRR and BRS, ► 2007
    143
  • 2.3 Vacuum system schematic diagram - engine codes BRR and BRS, 2008 ►
    144
  • 3 Air filter
    145
  • 3.1 Assembly overview - air filter
    145
  • 4 Intake manifold
    146
  • 4.1 Assembly overview - intake manifold, engine codes BRR and BRS
    146
  • 4.2 Assembly overview - intake manifold, engine codes AXB and AXC
    146
  • 5 Engine control unit
    148
  • 5.1 Removing and installing engine (motor) control unit J623
    148
  • Exhaust system
    150
  • 1 Exhaust pipes and silencers
    150
  • 1.1 Assembly overview - silencers/catalytic converters
    150
  • 1.2 Assembly overview - silencers/particulate filter
    151
  • 1.3 Separating exhaust pipes from silencers
    152
  • 2 Emission control
    153
  • 2.1 Assembly overview - emission control
    153
  • 2.2 Removing and installing particulate filter
    154
  • 3 Exhaust gas recirculation
    158
  • 3.1 Assembly overview - exhaust gas recirculation, engine codes AXB and AXC
    158
  • 3.2 Assembly overview - exhaust gas recirculation, engine codes BRR and BRS
    159
  • Glow plug system
    160
  • 1 Glow plug system
    160
  • 1.1 Removing and installing glow plugs Q10 / Q13
    160
  • 1.2 Checking glow plugs Q10 / Q13
    162
  • 1.3 Removing and installing engine speed sender G28
    164
  • 1.4 Removing and installing Hall sender G40
    165
Manufacturer's designation 4-cylinder diesel engine
Manufacturer Volkswagen
Suitable for California / Multivan / Transporter / Transporter/Kombi LR (2003 - 2007) / Transporter (2003 - 2007)
Suitable car types 7H, 7J
Engine code BRS, AXB, AXC
Category Reparaturanleitung

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