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

4-cylinder diesel engine (common rail)

For LT 35 Kombi 4025 / LT 28-35 Fahrgest. / LT 28-35 Kombi 3000 / LT 28-35 Kombi 3550 / LT 28-35 Kasten 2500 / LT 28-46 Kasten 3550 / LT 35-46 Kasten 4025 / ...

Original Volkswagen repair manual


16,11 €7% VAT incl.

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Language: English

Digital PDF file

2.259 KB

193 Sites

Detailed technical data

Immediately readable

This repair manual contains: Self-diagnosis, Fault memory, Measured value blocks, Removing and installing engine, Poly V-belt drive, Crankshaft sprockets and dual mass flywheel, Cylinder head, Charge air system with turbocharger, Repairing diesel direct injection system and Checking components and functions. Show more
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Repair manual 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number and cylinder 1
    1
  • 1.2 Engine data
    1
  • Self-diagnosis
    2
  • 1 Self-diagnosis
    2
  • 1.1 Features of self-diagnosis
    2
  • 1.2 Technical data of self-diagnosis
    2
  • 1.3 Connecting the fault reader
    3
  • 2 Fault memory
    7
  • 2.1 Reading event memory
    7
  • 2.2 Clearing event memory
    8
  • 3 Fault table: SAE P0 codes
    9
  • 4 Fault table: SAE P1 codes
    12
  • 5 Final control diagnosis
    26
  • 5.1 Performing final control diagnosis
    26
  • 6 Measured value blocks
    29
  • 6.1 Reading measured value block
    29
  • 6.2 Evaluating measured value blocks at idling speed and ignition on
    30
  • 6.3 Evaluating measured value blocks at full throttle
    38
  • Removing and installing engine
    44
  • 1 Removing and installing engine
    44
  • 1.1 Notes on removing
    46
  • 1.2 Securing engine to assembly stand
    49
  • 1.3 Notes on installing
    50
  • 1.4 Specified torques
    51
  • Crankshaft group
    52
  • 1 Dismantling and assembling engine
    52
  • 1.1 Part I
    53
  • 1.2 Part II
    54
  • 1.3 Part III
    55
  • 2 Poly V-belt drive
    57
  • 2.1 Removing and installing poly-V belt
    57
  • 3 Crankshaft sprockets and dual mass flywheel
    60
  • 3.1 Removing and installing crankshaft sprockets and dual mass flywheel
    61
  • 3.2 Checking camshaft sprockets, adjusting if necessary
    64
  • 3.3 Renewing crankshaft sprocket
    67
  • 3.4 Renewing the dual mass flywheel needle bearing
    69
  • 3.5 Renewing crankshaft oil seal - pulley end
    71
  • 3.6 Renewing crankshaft oil seal -flywheel end-
    73
  • 4 Removing and installing crankshaft
    77
  • 4.1 Crankshaft dimensions
    78
  • 5 Dismantling and assembling pistons and conrods
    79
  • 5.1 Cylinder dimension
    81
  • Cylinder head, valve gear
    83
  • 1 Cylinder head
    83
  • 1.1 Removing and installing cylinder head
    86
  • 1.2 Checking compression
    88
  • 2 Repairing valve gear
    90
  • 2.1 Checking valve guides
    93
  • 2.2 Removing and installing rocker fingers
    93
  • 2.3 Renewing valve stem seals
    94
  • 2.4 Removing and installing camshaft
    96
  • 2.5 Checking and adjusting valve clearance
    99
  • Lubrication
    101
  • 1 Removing and installing parts of lubrication system
    101
  • 1.1 Engine oil:
    101
  • 1.2 Checking oil pressure and oil pressure switch
    106
  • Cooling
    108
  • 1 Removing and installing parts of cooling system
    108
  • 1.1 Parts of cooling system, body side
    108
  • 1.2 Parts of cooling system - engine side
    111
  • 1.3 Draining and adding coolant
    112
  • 1.4 Removing and installing radiator
    114
  • 1.5 Removing and installing viscous fan
    115
  • Fuel supply system
    116
  • 1 Removing and installing parts of fuel supply system
    116
  • 1.1 Removing and installing fuel tank with attached components
    116
  • 1.2 Safety regulations for working on fuel supply
    118
  • 1.3 Rules for cleanliness
    118
  • 1.4 Emptying fuel tank
    118
  • 1.5 Removing and installing fuel tank
    119
  • 1.6 Repairing fuel filter
    122
  • 1.7 Removing and installing fuel delivery unit
    122
  • 1.8 Checking fuel system pressurisation pump G6
    123
  • 1.9 Repairing accelerator mechanism
    126
  • 1.10 Checking adjustment of accelerator position sender
    127
  • 1.11 Checking accelerator position sender G79
    128
  • Turbocharging/supercharging
    131
  • 1 Charge air system with turbocharger
    131
  • 1.1 Removing and installing turbocharger with attachments
    131
  • 1.2 Removing and installing parts of charge air cooling
    132
  • 1.3 Rules for cleanliness
    132
  • 1.4 Removing and installing turbocharger
    133
  • 1.5 Vacuum hose connection diagram
    135
  • 2 Boost pressure regulation
    137
  • 2.1 Checking charge pressure control
    137
  • Mixture preparation - injection
    141
  • 1 Repairing diesel direct injection system
    141
  • 1.1 Safety precautions
    141
  • 1.2 Rules for cleanliness
    142
  • 1.3 Overview of fitting locations
    142
  • 1.4 System layout
    144
  • 1.5 Removing and installing high-pressure pump
    144
  • 1.6 Removing and installing injector
    147
  • 2 Checking components and functions
    150
  • 2.1 Checking voltage supply for diesel direct injection system
    150
  • 2.2 Checking engine speed sender G28
    150
  • 2.3 Checking intake manifold pressure sender G71 and intake manifold temperature sender G72
    151
  • 2.4 Checking coolant temperature sender G62
    153
  • 2.5 Checking intake manifold temperature sender G72
    155
  • 2.6 Checking fuel pressure sender G247
    157
  • 2.7 Checking air mass meter G70
    158
  • 2.8 Checking intake manifold flap changeover
    160
  • 2.9 Checking camshaft position Hall sender G40
    162
  • 2.10 Checking injectors
    163
  • 2.11 Checking fuel pressure regulating valve N276
    164
  • 3 Checking additional signals
    166
  • 3.1 Checking speed signal
    166
  • 3.2 Checking signals from and to air conditioning system
    167
  • 3.3 Checking speed signal
    168
  • 3.4 Checking signal from brake light switch F and brake light switch F47
    168
  • 3.5 Checking signal from clutch pedal switch F36
    169
  • 4 Renewing, coding and matching engine control unit
    171
  • 4.1 Renewing diesel direct injection system control unit J248
    171
  • 4.2 Coding engine control unit
    172
  • 4.3 Activating maximum speed governor in engine electronics control unit
    173
  • 4.4 Adapting working speed governor
    175
  • 4.5 Activating cruise control system
    177
  • Exhaust system
    179
  • 1 Removing and installing parts of exhaust system
    179
  • 2 Exhaust gas recirculation system
    180
  • 2.1 Removing and installing parts of exhaust gas recirculation system
    180
  • 2.2 Checking exhaust gas recirculation valve
    181
  • 2.3 Checking exhaust gas recirculation system
    181
  • Glow plug system
    185
  • 1 Checking glow plug system
    185
Manufacturer's designation 4-cylinder diesel engine (common rail)
Manufacturer Volkswagen
Suitable for LT 28-35 Fahrgest 300 / LT 28-35 Fahrgest. / LT 28-35 Kasten 2500 / LT 28-35 Kombi 3000 / LT 28-35 Kombi 3550 / LT 28-46 Doppelkab 35 / LT 28-46 Fahrgest 355 / LT 28-46 Kasten 3550 / LT 35 Kombi 4025 / LT 35-46 Doppelkab 40 / LT 35-46 Fahrgest 402 / LT 35-46 Kasten 4025 (1996 - 2006)
Suitable car types 2D
Engine code BCQ
Category Reparaturanleitung

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