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

4-cylinder diesel engine (2.0 l engine, common rail)

For CRAFTER / LT 2006>

Original Volkswagen repair manual


34,66 €7% VAT incl.

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Language: English

Digital PDF file

12.529 KB

479 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Auxiliary drive, Pistons and conrods, Fully enclosing toothed belt guard, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Intake manifold, Injectors/high-pressure accumulator (rail), Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual CRAFTER / LT 2006> 4-cylinder diesel 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 precautions when working on charge air system
    2
  • 1.3 Safety regulations for working on fuel supply
    2
  • 1.4 Safety precautions when working on the SCR system
    3
  • 1.6 Safety measures when working on vehicles with a start/stop system
    4
  • 1.7 Safety precautions when working on fuel system
    4
  • 2 Identification
    5
  • 2.1 Engine number/engine data
    5
  • 3 Repair instructions
    7
  • 3.1 Rules for cleanliness when working on fuel supply system
    7
  • 3.2 Rules for cleanliness and instructions for working on fuel system
    7
  • 3.3 Rules for cleanliness during work on fuel system
    9
  • 3.4 Rules for cleanliness when working on the SCR system
    9
  • 3.5 General notes on the lubrication system
    10
  • 3.6 General notes on cooling system
    10
  • 3.7 General notes on fuel system
    11
  • 3.8 Notes on hose connections with screw-type clips
    12
  • Removing and installing engine
    14
  • 1 Removing and installing engine
    14
  • 1.1 Removing engine
    14
  • 1.2 Securing engine on engine and gearbox support
    24
  • 1.3 Removing engine, Crafter 4MOTION with Achleitner four-wheel drive
    25
  • 1.4 Installing engine
    36
  • 2 Assembly mountings
    38
  • 2.1 Assembly overview - assembly mountings
    38
  • 2.2 Supporting engine in installation position
    40
  • Crankshaft group
    43
  • 1 Cylinder block (pulley end)
    43
  • 1.1 Assembly overview - poly V-belt drive
    43
  • 1.2 Assembly overview - cylinder block (pulley end)
    47
  • 1.3 Assembly overview - sealing flange, belt pulley end
    49
  • 1.4 Removing and installing poly-V belt
    50
  • 1.5 Removing and installing tensioner for poly V-belt
    53
  • 1.6 Removing and installing poly V-belt for viscous fan
    54
  • 1.7 Removing and installing vibration damper
    57
  • 1.8 Removing and installing bracket for ancillaries
    58
  • 1.9 Removing and installing bracket with belt pulley
    60
  • 1.10 Renewing crankshaft oil seal - belt pulley end
    61
  • 1.11 Removing and installing sealing flange on pulley end
    64
  • 2 Cylinder block, gearbox end
    69
  • 2.1 Assembly overview - cylinder block, gearbox end
    69
  • 2.2 Removing and installing flywheel
    70
  • 2.3 Removing and installing sealing flange on gearbox side
    71
  • 3 Crankshaft
    83
  • 3.1 Assembly overview - crankshaft
    83
  • 3.2 Renewing needle bearing in crankshaft
    84
  • 3.3 Crankshaft dimensions
    86
  • 3.4 Measuring axial clearance of crankshaft
    87
  • 3.5 Measuring radial clearance of crankshaft
    88
  • 4 Auxiliary drive
    89
  • 4.1 Assembly overview - ancillary drive
    89
  • 4.2 Retrofitting auxiliary drive (genuine parts set)
    97
  • 4.3 Removing and installing poly V-belt for auxiliary drive
    101
  • 5 Pistons and conrods
    103
  • 5.1 Assembly overview - pistons and conrods
    103
  • 5.2 Measuring piston projection at TDC
    105
  • 5.3 Checking pistons and cylinder bores
    107
  • 5.4 Separating new conrod
    110
  • 5.5 Checking radial clearance of conrods
    110
  • 5.6 Installation position of bearing shells
    111
  • Cylinder head, valve gear
    112
  • 1 Cylinder head
    112
  • 1.1 Assembly overview - cylinder head
    112
  • 1.2 Assembly overview - cylinder head cover
    116
  • 1.3 Removing and installing cylinder head
    118
  • 1.4 Removing and installing cylinder head cover
    130
  • 1.5 Removing and installing injector seals
    136
  • 1.6 Removing and installing vacuum pump
    137
  • 1.7 Checking compression
    139
  • 2 Fully enclosing toothed belt guard
    141
  • 2.1 Assembly overview - fully enclosing toothed belt guard
    141
  • 2.2 Removing and installing upper toothed belt guard (fully enclosing)
    143
  • 2.3 Removing and installing lower toothed belt guard (fully enclosed)
    144
  • 2.4 Removing and installing rear toothed belt guard (fully enclosing)
    146
  • 3 Toothed belt drive
    150
  • 3.1 Assembly overview - toothed belt
    150
  • 3.2 Removing and installing toothed belt
    152
  • 4 Valve gear
    167
  • 4.1 Assembly overview - valve gear
    167
  • 4.2 Removing and installing valve stem seals
    169
  • 4.3 Renewing valve stem seals with cylinder head removed
    174
  • 4.4 Removing and installing camshaft
    177
  • 4.5 Measuring axial play of camshaft
    186
  • 4.6 Measuring radial play of camshaft
    187
  • 4.7 Removing and installing camshaft oil seal
    187
  • 4.8 Checking hydraulic compensation elements
    192
  • 5 Inlet and exhaust valves
    194
  • 5.1 Reworking valve seats
    194
  • 5.2 Checking valve guides
    194
  • 5.3 Checking valves
    195
  • 5.4 Valve dimensions
    195
  • Lubrication
    196
  • 1 Sump, oil pump
    196
  • 1.1 Assembly overview - sump/oil pump
    196
  • 1.2 Removing and installing oil sump
    199
  • 1.3 Removing and installing oil pump
    203
  • 1.4 Engine oil:
    204
  • 1.5 Removing and installing oil level and oil temperature sender G266
    204
  • 1.6 Measuring oil consumption
    205
  • 2 Oil filter, oil pressure switch
    206
  • 2.1 Assembly overview - oil filter housing with engine oil cooler
    206
  • 2.2 Removing and installing engine oil cooler
    208
  • 2.3 Removing and installing oil filter housing
    210
  • 2.4 Removing and installing oil pressure switch F1
    212
  • 2.5 Checking oil pressure switch F1
    213
  • 2.6 Checking oil pressure
    215
  • 3 Oil circuit
    217
  • 3.1 Removing and installing oil supply line, single turbo
    217
  • 3.2 Removing and installing oil supply line, bi-turbo
    218
  • Cooling
    223
  • 1 Cooling system/coolant
    223
  • 1.1 Connection diagram - coolant hoses
    223
  • 1.2 Draining and adding coolant
    233
  • 1.3 Checking cooling system for leaks
    242
  • 2 Coolant pump, regulation of cooling system
    245
  • 2.1 Assembly overview - coolant pump, thermostat
    245
  • 2.2 Assembly overview - electric coolant pump
    245
  • 2.3 Removing and installing coolant pump
    246
  • 2.4 Removing and installing 4/2-way valve with thermostat
    248
  • 2.5 Removing and installing coolant temperature sender G62
    251
  • 2.6 Removing and installing radiator outlet coolant temperature sender G83
    252
  • 2.7 Removing and installing coolant flange
    253
  • 2.8 Removing and installing Y-thermostat
    255
  • 2.9 Removing and installing coolant circulation pump V50
    257
  • 2.10 Removing and installing 3/2-way valve, Euro 6 vehicles
    258
  • 3 Coolant pipes/coolant hoses
    260
  • 3.1 Assembly overview - coolant pipe/coolant hose
    260
  • 3.2 Removing and installing coolant pipe with coolant hose
    261
  • 4 Radiator, radiator fan
    265
  • 4.1 Assembly overview - radiator/radiator fan
    265
  • 4.2 Assembly overview - viscous fan
    266
  • 4.3 Removing and installing viscous fan
    268
  • 4.4 Removing and installing cowling
    271
  • 4.5 Removing and installing radiator
    272
  • Turbocharging/supercharging
    276
  • 1 Turbocharger
    276
  • 1.1 Assembly overview - turbocharger, single turbo
    276
  • 1.2 Assembly overview - turbocharger, bi-turbo
    279
  • 1.3 Removing and installing turbocharger, single turbo
    282
  • 1.4 Removing and installing turbocharger, bi-turbo
    288
  • 1.6 Assembly overview - turbocharger, bi-turbo, dismantling
    303
  • 1.7 Renewing gasket between bi-turbo turbine housings
    306
  • 1.8 Removing and installing regulating flap potentiometer G584
    310
  • 1.9 Renewing vacuum unit for turbocharger
    317
  • 2 Charge air system
    324
  • 2.1 Assembly overview - charge air system
    324
  • 2.2 Removing and installing charge air cooler
    326
  • 2.5 Removing and installing charge pressure control solenoid valve N75
    328
  • 2.6 Removing and installing exhaust gas flap valve N220
    329
  • 2.7 Removing and installing charge air pipe
    330
  • 2.8 Checking charge air system for leaks
    332
  • Mixture preparation - injection
    336
  • 1 Injection system
    336
  • 1.1 Schematic overview - fuel system
    336
  • 1.2 Overview of fitting locations - injection system
    338
  • 1.3 Checking fuel system for leaks
    345
  • 2 Vacuum system
    346
  • 2.1 Connection diagram - vacuum system
    346
  • 3 Intake manifold
    349
  • 3.1 Assembly overview – intake manifold
    349
  • 3.2 Removing and installing intake manifold
    350
  • 3.3 Removing and installing throttle valve module J338
    354
  • 4 Air filter
    356
  • 4.1 Assembly overview - air filter housing
    356
  • 4.2 Removing and installing air filter housing
    357
  • 5 Injectors/high-pressure accumulator (rail)
    358
  • 5.1 Assembly overview - injectors
    358
  • 5.2 Removing and installing injectors
    361
  • 5.3 Adapting correction values for injectors
    366
  • 5.4 Testing injectors
    367
  • 5.5 Testing jammed-open injectors
    367
  • 5.6 Checking return flow rate of injectors with engine running
    369
  • 5.7 Checking return flow rate of injectors at starter speed
    372
  • 5.8 Removing and installing fuel rail
    374
  • 5.9 Removing and installing high-pressure lines
    377
  • 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
    387
  • 7 Engine control unit
    389
  • 7.1 Removing and installing engine control unit J623
    389
  • 7.2 Removing and installing engine (motor) control unit J623 with protective housing
    390
  • 8 High-pressure pump
    392
  • 8.1 Assembly overview - high-pressure pump
    392
  • 8.2 Removing and installing high-pressure pump
    394
  • 8.3 Initial fuel filling after installation of the high-pressure pump
    397
  • 8.4 Checking high-pressure pump
    398
  • 9 Lambda probe
    401
  • 9.1 Removing and installing Lambda probe
    401
  • Exhaust system
    405
  • 1 Exhaust pipes and silencers
    405
  • 1.1 Assembly overview – silencers
    405
  • 1.5 Checking exhaust system for leaks
    409
  • 1.6 Removing and installing rear silencer
    409
  • 2 Emission control
    418
  • 2.1 Assembly overview – emission control
    418
  • 2.2 Removing and installing particulate filter
    420
  • 3 SCR system (selective catalytic reduction)
    428
  • 3.1 Assembly overview – reducing agent tank
    428
  • 3.2 Removing and installing reducing agent tank
    430
  • 3.3 Removing and installing reducing agent supply line
    432
  • 3.4 Removing and installing injector for reduction agent N474
    435
  • 3.5 Removing and installing control unit for reducing-agent heater J891
    436
  • 3.6 Removing and installing delivery unit for reducing agent metering system GX19
    437
  • 3.7 Draining reducing agent tank
    441
  • 3.8 Removing and installing filler neck for reducing agent
    444
  • 3.9 Removing and installing NOx sender G295/control unit for NOx sender J583
    445
  • 3.10 Removing and installing NOx sender 2 G687/control unit for NOx sender 2 J881
    447
  • 3.11 Removing and installing exhaust gas temperature sender 2 G448
    450
  • 4 Exhaust gas recirculation
    453
  • 4.1 Assembly overview – exhaust gas recirculation
    453
  • 4.2 Removing and installing exhaust gas recirculation valve N18
    454
  • 4.3 Removing and installing exhaust gas recirculation cooler
    455
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    458
  • 4.5 Removing and installing pump for exhaust gas recirculation cooler V400
    462
  • 4.6 Removing and installing exhaust gas recirculation temperature sensor G98
    463
  • Glow plug system
    465
  • 1 Glow plug system
    465
  • 1.1 Removing and installing glow plug
    465
  • 1.2 Checking glow plug system
    467
  • 1.3 Removing and installing Hall sender G40
    467
  • 1.4 Removing and installing engine speed sender G28
    469
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for CRAFTER (2006 - 2007) / LT 2006> (2006 - 2007)
Suitable car types 2F, 2E
Engine code CKUB, CKTB, CKTC, CSLA, CSLC, CSLB, CSNA
Category Reparaturanleitung

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