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

For CRAFTER / LT 2006>

Original Volkswagen repair manual


16,84 €7% VAT incl.

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Immediately available for download

Language: English

Digital PDF file

4.628 KB

203 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Cylinder block (pulley end), Power take-off, Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Engine oil cooler, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Injectors/high-pressure accumulator (rail) and SCR system (selective catalytic reduction). Show more
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Repair manual CRAFTER / LT 2006> 5-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number/engine data
    1
  • 2 Safety information
    3
  • 2.1 Safety measures when working on fuel supply
    3
  • 2.3 Safety precautions when working on the cooling system
    4
  • 2.4 Safety precautions when working on charge air system
    5
  • 2.5 Safety precautions when working on injection system
    5
  • 2.6 Safety precautions when working on the SCR system
    6
  • 3 Repair instructions
    7
  • 3.1 Rules for cleanliness when working on fuel supply system
    7
  • 3.2 Rules for cleanliness during work on fuel system
    7
  • 3.3 Rules for cleanliness and instructions for working on injection system
    7
  • 3.4 General notes on the lubrication system
    9
  • 3.5 Foreign objects in engine
    9
  • Removing and installing engine
    10
  • 1 Removing and installing engine
    10
  • 1.1 Removing engine
    10
  • 1.2 Installing engine
    14
  • 1.3 Securing engine on engine and gearbox support VAS 6095
    16
  • Crankshaft group
    17
  • 1 Cylinder block (pulley end)
    17
  • 1.1 Assembly overview - cylinder block (pulley end)
    17
  • 1.2 Assembly overview – poly V-belt drive
    18
  • 1.3 Removing and installing poly-V belt
    19
  • 1.4 Removing and installing tensioner for poly V-belt
    20
  • 1.5 Renewing crankshaft oil seal - belt pulley end
    21
  • 2 Cylinder block, gearbox end
    24
  • 2.1 Assembly overview - flywheel
    24
  • 2.2 Removing and installing sealing flange on gearbox side
    26
  • 2.3 Removing and installing flywheel
    34
  • 2.4 Renewing needle bearing
    35
  • 3 Power take-off
    37
  • 3.1 Engine power take-off
    37
  • 3.2 Removing and installing poly V-belt for power take-off
    37
  • 4 Crankshaft
    40
  • 4.1 Assembly overview - crankshaft
    40
  • 4.2 Crankshaft dimensions
    41
  • 5 Pistons and conrods
    42
  • 5.1 Assembly overview - pistons and conrods
    42
  • 5.2 Checking pistons and cylinder bores
    43
  • 5.3 Measuring piston projection at TDC
    44
  • 5.4 Piston and cylinder dimensions
    45
  • Cylinder head, valve gear
    46
  • 1 Cylinder head
    46
  • 1.1 Assembly overview - cylinder head
    46
  • 1.2 Removing and installing cylinder head
    49
  • 1.3 Removing and installing cylinder head cover
    53
  • 1.4 Checking compression
    54
  • 2 Toothed belt drive
    56
  • 2.1 Assembly overview - toothed belt
    56
  • 2.2 Removing and installing toothed belt
    58
  • 3 Valve gear
    64
  • 3.1 Assembly overview - valve gear
    64
  • 3.2 Measuring axial play of camshaft
    65
  • 3.3 Removing and installing camshaft
    66
  • 3.4 Removing and installing valve stem seals
    67
  • 4 Inlet and exhaust valves
    70
  • 4.1 Reworking valve seats
    70
  • 4.2 Checking valve guides
    71
  • 4.3 Removing and installing valve guides
    71
  • 4.4 Valve dimensions
    73
  • Lubrication
    74
  • 1 Sump, oil pump
    74
  • 1.1 Assembly overview - sump/oil pump
    74
  • 1.2 Removing and installing sump
    76
  • 1.3 Removing and installing oil pump
    80
  • 1.4 Measuring oil consumption
    83
  • 1.5 Engine oil:
    83
  • 2 Engine oil cooler
    85
  • 2.1 Checking engine oil cooler for leaks
    85
  • 3 Oil filter, oil pressure switch
    87
  • 3.1 Checking oil pressure and oil pressure switch
    87
  • Cooling
    89
  • 1 Cooling system/coolant
    89
  • 1.1 Connection diagram - coolant hoses
    89
  • 1.2 Coolant hose schematic diagram, vehicles with auxiliary heater
    90
  • 1.3 Coolant hose schematic diagram, vehicles with auxiliary heater and 2nd heat exchanger
    91
  • 1.4 Checking cooling system for leaks
    91
  • 1.5 Draining and adding coolant
    93
  • 2 Coolant pump, regulation of cooling system
    101
  • 2.1 Assembly overview - coolant pump, thermostat
    101
  • 2.2 Removing and installing coolant pump
    103
  • 2.3 Removing and installing thermostat
    104
  • 3 Radiator, radiator fan
    106
  • 3.1 Assembly overview - radiator/radiator fan
    106
  • 3.2 Removing and installing radiator
    107
  • 3.3 Removing and installing viscous fan
    108
  • Turbocharging/supercharging
    110
  • 1 Turbocharger
    110
  • 1.1 Assembly overview - turbocharger (engine codes BJJ, BJK, BJL, BJM)
    110
  • 1.2 Assembly overview - turbocharger (engine codes CEBA, CEBB, CECA, CECB)
    112
  • 1.3 Removing and installing turbocharger (engine codes BJJ, BJK, BJL, BJM)
    114
  • 2 Charge air system
    118
  • 2.1 Assembly overview - charge air system
    118
  • 2.2 Checking charge air system for leaks
    118
  • Mixture preparation - injection
    122
  • 1 Injection system
    122
  • 1.1 Schematic overview - fuel system
    122
  • 1.2 Assembly overview - fuel system
    123
  • 1.3 Filling fuel system
    126
  • 1.4 Checking fuel system for leaks
    126
  • 2 Injectors/high-pressure accumulator (rail)
    128
  • 2.1 Check pressure retention valve in fuel return line
    128
  • 2.2 Removing and installing injectors (piezo injectors)
    129
  • 2.3 Removing and installing fuel overflow valve
    132
  • 3 Vacuum system
    136
  • 3.1 Connection diagram - vacuum system
    136
  • 4 High-pressure pump
    137
  • 4.1 Removing and installing high-pressure pump
    137
  • 5 Senders and sensors
    140
  • 5.1 Removing and installing fuel pressure regulating valve N276
    140
  • 5.2 Checking fuel pressure regulating valve N276
    142
  • 5.3 Removing and installing fuel pressure sender G247
    142
  • 5.4 Removing and installing fuel metering valve N290
    144
  • 5.5 Removing and installing air mass meter G70
    149
  • 6 Intake manifold
    150
  • 6.1 Assembly overview - intake manifold
    150
  • 6.2 Removing and installing intake manifold
    151
  • 7 Air filter
    153
  • 7.1 Assembly overview - air filter
    153
  • 8 Engine control unit
    154
  • 8.1 Removing and installing engine control unit J623
    154
  • Exhaust system
    155
  • 1 Exhaust pipes and silencers
    155
  • 1.1 Assembly overview - silencer (engine codes BJJ, BJK, BJL, BJM)
    155
  • 1.3 Checking exhaust system for leaks
    157
  • 2 Emission control
    158
  • 2.1 Assembly overview - diesel particulate filter (engine codes CEBA, CEBB, CECA, CECB)
    158
  • 2.2 Assembly overview - diesel particulate filter (engine codes BJJ, BJK, BJL, BJM)
    160
  • 2.5 Removing and installing catalytic converter (engine codes BJJ, BJK, BJL, BJM)
    169
  • 3 SCR system (selective catalytic reduction)
    172
  • 3.1 AdBlue® technology
    172
  • 3.2 Assembly overview - tank for reducing agent (Crafter panel van and Crafter window van)
    172
  • 3.4 Removing and installing injector for reduction agent N474
    176
  • 3.5 Removing and installing reducing agent supply line
    177
  • 3.7 Removing and installing filler neck for reducing agent (panel van and window van)
    181
  • 3.8 Removing and installing reducing agent tank (panel van and window van)
    181
  • 3.9 Removing and installing reducing agent tank (platform van and chassis)
    183
  • 3.10 Emptying reducing agent tank (panel van and window van)
    184
  • 3.11 Emptying reducing agent tank (platform van and chassis)
    185
  • 3.12 Removing and installing heater element (heater cup)
    187
  • 4 Exhaust gas recirculation
    190
  • 4.1 Assembly overview - exhaust gas recirculation
    190
  • Glow plug system
    192
  • 1 Glow plug system
    192
  • 1.1 Handling ceramic glow plugs
    192
  • 1.2 Checking glow plugs (installed)
    192
  • 1.3 Checking glow plugs (removed)
    192
  • 1.4 Removing and installing glow plugs
    193
  • 1.5 Removing and installing engine speed sender G28
    197
Manufacturer's designation 5-cylinder diesel engine
Manufacturer Volkswagen
Suitable for CRAFTER (2006 - 2007) / LT 2006> (2006 - 2007)
Suitable car types 2F, 2E
Engine code BJK, BJL, BJM, CEBA, CEBB, CECA, CECB
Category Reparaturanleitung

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