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  • Examplepage for repair manual 4-cylinder diesel engine (distributor-type injection pump)
  • Examplepage for repair manual 2 4-cylinder diesel engine (distributor-type injection pump)
  • Examplepage for repair manual 3 4-cylinder diesel engine (distributor-type injection pump)
  • Examplepage for repair manual 4-cylinder diesel engine (distributor-type injection pump)
  • Examplepage for repair manual 2 4-cylinder diesel engine (distributor-type injection pump)
  • Examplepage for repair manual 3 4-cylinder diesel engine (distributor-type injection pump)

4-cylinder diesel engine (distributor-type injection pump)

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


9,98 €7% VAT incl.

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Language: English

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2.029 KB

108 Sites

Detailed technical data

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This repair manual contains: Removing and installing engine, Cylinder head and Parts of lubrication system. 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
  • Removing and installing engine
    2
  • 1 Removing and installing engine
    2
  • 1.1 Notes on removing
    4
  • 1.2 Securing engine to assembly stand
    7
  • 1.3 Notes on installing
    7
  • 1.4 Specified torques
    8
  • Crankshaft group
    9
  • 1 Dismantling and assembling engine
    9
  • 1.1 Assembly overview
    9
  • 1.2 Part I
    10
  • 1.3 Part II
    11
  • 1.4 Part III
    12
  • 1.5 Part IV
    13
  • 1.6 Removing and installing poly-V belt
    14
  • 1.7 Removing, installing and checking tensioning device for poly V-belt
    15
  • 2 Removing and installing crankshaft sprockets and dual mass flywheel
    17
  • 2.1 Assembly overview
    17
  • 2.2 Part I
    18
  • 2.3 Part II
    19
  • 2.4 Checking camshaft sprockets, adjusting if necessary
    20
  • 2.5 Renewing crankshaft pulley
    23
  • 2.6 Renewing the dual mass flywheel needle bearing
    25
  • 2.7 Renewing crankshaft oil seal - pulley end
    27
  • 2.8 Renewing crankshaft oil seal -flywheel end-
    29
  • 3 Removing and installing crankshaft
    33
  • 3.1 Crankshaft dimensions
    34
  • 4 Dismantling and assembling pistons and conrods
    35
  • 4.1 Cylinder dimension
    37
  • Cylinder head, valve gear
    39
  • 1 Cylinder head
    39
  • 1.1 Assembly overview
    40
  • 1.2 Removing and installing cylinder head
    41
  • 1.3 Checking compression
    43
  • 2 Repairing valve gear
    46
  • 2.1 Checking valve guides
    49
  • 2.2 Removing and installing rocker fingers
    49
  • 2.3 Renewing valve stem seals
    50
  • 2.4 Removing and installing camshaft
    52
  • 2.5 Checking and adjusting valve clearance
    55
  • Lubrication
    57
  • 1 Parts of lubrication system
    57
  • 1.1 Engine oil:
    57
  • 1.2 Assembly overview
    57
  • 1.3 Part I
    57
  • 1.4 Part II
    60
  • 1.5 Checking oil pressure and oil pressure switch
    61
  • Cooling
    63
  • 1 Parts of cooling system
    63
  • 1.1 Parts of cooling system, body side
    63
  • 1.2 Parts of cooling system - engine side
    65
  • 1.3 Draining and adding coolant
    66
  • 1.4 Removing and installing radiator
    69
  • 1.5 Removing and installing viscous fan
    70
  • Fuel supply system
    71
  • 1 Parts of fuel supply system
    71
  • 1.1 Removing and installing fuel tank with attached components
    71
  • 1.2 Safety regulations for working on fuel supply
    72
  • 1.3 Rules for cleanliness
    73
  • 1.4 Removing and installing fuel tank
    73
  • 1.5 Removing and installing fuel gauge sender G
    75
  • 1.6 Repairing accelerator mechanism
    76
  • Turbocharging/supercharging
    78
  • 1 Charge air system with turbocharger
    78
  • 1.1 Removing and installing turbocharger with attachments
    78
  • 1.2 Removing and installing parts of charge air cooling
    79
  • 1.3 Rules for cleanliness
    80
  • 1.4 Removing and installing turbocharger
    80
  • 1.5 Checking turbocharger
    82
  • Mixture preparation - injection
    84
  • 1 Repairing diesel direct injection system
    84
  • 1.1 Safety precautions
    84
  • 1.2 Rules for cleanliness
    84
  • 1.3 Repairing injection pump
    84
  • 1.4 Repairing fuel filter
    87
  • 1.5 Removing and installing injection pump
    88
  • 1.6 Removing and installing injection pump sprocket
    91
  • 1.8 Adjusting idling speed and governed speed
    96
  • 1.9 Removing and installing injectors
    97
  • 1.10 Repairing injectors
    99
  • Exhaust system
    101
  • 1 Removing and installing parts of exhaust system
    101
  • Glow plug system
    102
  • 1 Glow plug system
    102
  • 1.1 Checking glow plug system
    102
  • 1.2 Checking glow plugs
    103
Manufacturer's designation 4-cylinder diesel engine (distributor-type injection pump)
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 ATA
Category Reparaturanleitung

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