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  • Examplepage for repair manual 3 5-cylinder diesel engine
  • Examplepage for repair manual 5-cylinder diesel engine
  • Examplepage for repair manual 2 5-cylinder diesel engine
  • Examplepage for repair manual 3 5-cylinder diesel engine

5-cylinder diesel engine

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


19,15 €7% VAT incl.

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Language: English

Digital PDF file

3.852 KB

235 Sites

Detailed technical data

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This repair manual contains: Self-diagnosis, Fault memory, Measured value blocks, Removing and installing engine, Charge air system with turbocharger, Repairing diesel direct injection system, Checking components and functions and Glow plug system. Show more
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Repair manual 5-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Self-diagnosis
    3
  • 1 Self-diagnosis
    3
  • 1.1 Features of self-diagnosis
    3
  • 1.2 Technical data of self-diagnosis
    3
  • 1.3 Connecting vehicle diagnosis, testing and information system VAS 5051
    4
  • 2 Fault memory
    6
  • 2.1 Reading and erasing fault memory
    6
  • 3 Fault table: V.A.G codes
    7
  • 4 Fault table: SAE P codes
    17
  • 5 Final control diagnosis
    30
  • 5.1 Performing final control diagnosis
    30
  • 6 Measured value blocks
    33
  • 6.1 Safety precautions
    33
  • 6.2 Read measured value block
    33
  • 6.5 Evaluating read measured value blocks at idling speed, engine code AGX
    49
  • 6.6 Evaluating read measured value blocks at full throttle, engine code AGX
    57
  • Removing and installing engine
    61
  • 1 Removing and installing engine
    61
  • 1.1 Removing engine
    61
  • 1.2 Securing engine on engine and gearbox support
    66
  • 1.3 Installing engine
    66
  • 1.4 Additional information and assembly work for vehicles with air conditioner
    68
  • Crankshaft group
    70
  • 1 Dismantling and assembling engine
    70
  • 1.1 Overview
    70
  • 1.2 Removing and installing poly-V belt
    76
  • 1.3 Removing and installing tensioner for poly V-belt
    77
  • 2 Removing and installing sealing flange and flywheel
    78
  • 2.1 Renewing crankshaft oil seal - pulley end
    79
  • 3 Removing and installing crankshaft
    82
  • 3.1 Crankshaft dimensions
    83
  • 3.2 Pulling needle roller bearing out of and driving into crankshaft
    83
  • 4 Dismantling and assembling pistons and conrods
    85
  • 4.1 Checking piston projection at TDC
    87
  • 4.2 Piston and cylinder dimensions
    89
  • Cylinder head, valve gear
    90
  • 1 Removing and installing cylinder head
    90
  • 1.1 Installing cylinder head
    92
  • 1.2 Removing and installing camshaft toothed belt
    94
  • 1.3 Checking compression
    99
  • 2 Repairing valve gear
    102
  • 2.1 Reworking valve seats
    104
  • 2.2 Checking valve guides
    105
  • 2.3 Renewing valve guides
    106
  • 2.4 Renewing valve stem seals
    107
  • 2.5 Removing and installing camshaft
    109
  • 2.6 Checking hydraulic bucket tappets
    110
  • Lubrication
    112
  • 1 Removing and installing parts of lubrication system
    112
  • 1.1 Engine oil:
    112
  • 1.2 Overview
    112
  • 1.3 Checking oil pressure and oil pressure switch
    117
  • Cooling
    119
  • 1 Removing and installing parts of cooling system
    119
  • 1.1 Parts of cooling system, body side
    119
  • 1.2 Parts of cooling system - engine side
    121
  • 1.3 Coolant hose schematic diagram
    123
  • 1.4 Draining and adding coolant
    124
  • 1.5 Removing and installing radiator
    126
  • 1.6 Removing and installing viscous fan coupling
    128
  • Fuel supply system
    131
  • 1 Removing and installing parts of fuel supply system
    131
  • 1.1 Removing and installing fuel tank with attached components
    131
  • 1.2 Repairing fuel filter
    132
  • 1.3 Safety measures when working on fuel supply
    133
  • 1.4 Rules for cleanliness
    133
  • 1.5 Emptying fuel tank
    134
  • 1.6 Removing and installing fuel tank
    134
  • 1.7 Removing and installing fuel delivery unit
    137
  • 1.8 Repairing accelerator mechanism
    138
  • 1.9 Checking adjustment of accelerator position sender
    139
  • 1.10 Checking accelerator position sender
    140
  • Turbocharging/supercharging
    143
  • 1 Charge air system with turbocharger
    143
  • 1.1 Removing and installing turbocharger with attachments
    143
  • 1.2 Removing and installing parts of charge air cooling
    147
  • 1.3 Removing and installing turbocharger
    148
  • 2 Checking charge pressure system
    152
  • 2.1 Checking charge pressure control
    152
  • Mixture preparation - injection
    157
  • 1 Repairing diesel direct injection system
    157
  • 1.1 Safety precautions
    157
  • 1.2 Rules for cleanliness
    158
  • 1.3 Overview of fitting locations
    158
  • 1.4 Removing and installing injection pump toothed belt
    160
  • 1.5 Repairing injection pump
    160
  • 1.6 Repairing intake manifold flap
    162
  • 1.7 Removing, installing and tensioning injection pump toothed belt
    164
  • 1.8 Removing and installing injection pump
    167
  • 1.9 Dynamically checking and adjusting commencement of injection
    170
  • 1.10 Removing and installing injectors
    173
  • 1.11 Repairing injectors
    174
  • 1.12 Renewing injection timing device cover O-ring
    175
  • 2 Checking components and functions
    176
  • 2.1 Connecting test box
    176
  • 2.2 Checking voltage supply for diesel direct injection system
    177
  • 2.3 Checking engine speed sender
    178
  • 2.4 Checking intake manifold pressure sender and altitude sender
    179
  • 2.5 Checking coolant temperature sender
    182
  • 2.6 Checking intake manifold temperature sender
    184
  • 2.7 Checking fuel temperature sender
    186
  • 2.8 Checking modulating piston movement sender and metering adjuster
    188
  • 2.9 Checking needle lift sender
    192
  • 2.10 Checking injection timing control range
    194
  • 2.11 Checking air mass meter
    198
  • 2.12 Checking intake manifold flap changeover
    201
  • 3 Checking additional signals
    204
  • 3.1 Checking speed signal
    204
  • 3.2 Checking signals from and to air conditioning system
    205
  • 3.3 Checking speed signal
    206
  • 3.4 Checking signal from brake light switch and brake pedal switch
    207
  • 3.5 Checking signal from clutch pedal switch
    208
  • 4 Renewing, coding and matching engine control unit
    210
  • 4.1 Renewing engine control unit
    210
  • 4.2 Coding engine control unit
    210
  • 4.3 Activating maximum speed governor in engine electronics control unit
    211
  • 4.4 Activating cruise control system
    213
  • Exhaust system
    214
  • 1 Removing and installing parts of exhaust system
    214
  • 1.1 Overview
    214
  • 2 Exhaust gas recirculation system
    219
  • 2.1 Removing and installing parts of exhaust gas recirculation system
    219
  • 2.2 Vacuum hose schematic diagram
    220
  • 2.3 Checking exhaust gas recirculation valve
    221
  • 2.4 Checking exhaust gas recirculation system
    222
  • Glow plug system
    228
  • 1 Glow plug system
    228
  • 1.1 Checking glow plug system
    228
  • 1.2 Checking glow plugs
    228
Manufacturer's designation 5-cylinder diesel engine
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 AHD, ANJ, APA, AVR, BBE, BBF
Category Reparaturanleitung

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