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  • 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 California / Multivan / Transporter / Transporter/Kombi LR

Original Volkswagen repair manual


16,33 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

3.095 KB

196 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Injectors, Intake manifold and Exhaust gas temperature regulation. Show more
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Repair manual 5-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification
    1
  • 1.1 Engine number/engine data
    1
  • 2 Safety information
    2
  • 2.2 Safety precautions when working on the cooling system
    2
  • 2.3 Safety regulations for working on fuel supply
    3
  • 2.4 Safety precautions when working on injection system
    4
  • 3 Repair instructions
    5
  • 3.1 Rules for cleanliness during work on fuel system
    5
  • 3.2 Rules for cleanliness when working on fuel supply system
    5
  • 3.3 Rules for cleanliness when working on injection system
    6
  • 3.4 Foreign objects in engine
    6
  • Removing and installing engine
    7
  • 1 Removing and installing engine
    7
  • 1.1 Removing engine
    7
  • 1.2 Securing engine to assembly stand
    13
  • 1.3 Installing engine
    14
  • 2 Assembly mountings
    17
  • 2.1 Assembly overview - assembly mountings
    17
  • 2.2 Removing and installing front torque reaction support
    18
  • Crankshaft group
    20
  • 1 Cylinder block (pulley end)
    20
  • 1.1 Assembly overview - crankcase
    20
  • 1.2 Crankcase - attachments
    22
  • 1.3 Removing and installing sealing flange on pulley end
    24
  • 1.4 Renewing seal for timing housing cover
    25
  • 1.5 Renewing alternator shaft oil seal
    26
  • 1.6 Removing and installing thread insert for tie bolt
    29
  • 2 Cylinder block, gearbox end
    30
  • 2.1 Assembly overview – valve timing housing cover
    30
  • 2.2 Removing and installing drive plate
    32
  • 2.3 Removing and installing flywheel
    33
  • 3 Crankshaft
    36
  • 3.1 Assembly overview - crankshaft
    36
  • 3.2 Basic settings for gear train
    38
  • 3.3 Crankshaft bearing cap identification
    40
  • 3.4 Crankshaft dimensions
    41
  • 3.5 Measuring axial clearance of crankshaft
    41
  • 3.6 Measuring radial clearance of crankshaft
    42
  • 4 Pistons and conrods
    43
  • 4.1 Assembly overview - pistons and conrods
    43
  • 4.2 Installation position and allocation of piston to cylinder
    45
  • 4.3 Measuring piston projection at TDC
    45
  • 4.4 Checking piston ring gap
    46
  • 4.5 Checking ring-to-groove clearance
    47
  • 4.6 Checking cylinder bores
    47
  • 4.7 Piston and cylinder dimensions
    48
  • Cylinder head, valve gear
    49
  • 1 Cylinder head
    49
  • 1.1 Assembly overview - cylinder head
    49
  • 1.2 Removing and installing cylinder head
    54
  • 1.3 Checking valve timing
    58
  • 1.4 Checking compression
    60
  • 2 Valve gear
    62
  • 2.1 Assembly overview - valve gear
    62
  • 2.2 Measuring axial play of camshaft
    65
  • 2.3 Removing and installing camshaft
    66
  • 2.4 Removing and installing camshaft drive gear
    67
  • 2.5 Removing and installing valve stem seals
    72
  • 3 Inlet and exhaust valves
    75
  • 3.1 Reworking valve seats
    75
  • 3.2 Checking valve guides
    76
  • 3.3 Valve dimensions
    77
  • Lubrication
    79
  • 1 Sump, oil pump
    79
  • 1.1 Assembly overview - sump/oil pump
    79
  • 1.2 Removing and installing oil sump
    81
  • 1.3 Engine oil:
    83
  • 2 Oil filter, oil pressure switch
    85
  • 2.1 Assembly overview - oil filter housing
    85
  • 2.2 Removing and installing oil filter housing
    86
  • 2.3 Checking oil pressure and oil pressure switch
    90
  • 2.4 Measuring oil consumption
    92
  • Cooling
    93
  • 1 Cooling system/coolant
    93
  • 1.1 Connection diagram - coolant hoses
    93
  • 1.2 Draining and adding coolant
    93
  • 1.3 Checking cooling system for leaks
    101
  • 2 Coolant pump, regulation of cooling system
    103
  • 2.1 Assembly overview - coolant pump, thermostat
    103
  • 2.2 Removing and installing coolant temperature sender G62
    105
  • 2.3 Removing and installing thermostat housing
    107
  • 2.4 Removing and installing coolant pump
    107
  • 2.5 Removing and installing coolant union
    112
  • 2.6 Renewing pipe connection for coolant
    113
  • 3 Radiator, radiator fan
    115
  • 3.1 Assembly overview - radiator, radiator fan
    115
  • 3.2 Assembly overview – fan support
    117
  • 3.3 Removing and installing radiator
    117
  • Turbocharging/supercharging
    120
  • 1 Turbocharger
    120
  • 1.1 Assembly overview - turbocharger
    120
  • 1.2 Assembly overview - turbocharger
    122
  • 1.3 Removing and installing turbocharger
    124
  • 1.4 Removing and installing turbocharger
    126
  • 2 Charge air system
    131
  • 2.1 Assembly overview - charge air system
    131
  • 2.2 Checking charge air system for leaks
    132
  • 2.3 Installing hose connections with plug-in connectors
    135
  • Mixture preparation - injection
    137
  • 1 Injection system
    137
  • 1.1 Bleeding fuel system
    137
  • 2 Injectors
    138
  • 2.1 Assembly overview - unit injector
    138
  • 2.2 Removing and installing unit injector
    138
  • 2.3 Removing and installing wiring harness for unit injectors
    142
  • 2.4 Removing and installing O-rings for unit injector
    145
  • 2.5 Visual inspection of unit injector
    147
  • 3 Vacuum system
    148
  • 3.1 Vacuum hose schematic diagram
    148
  • 3.2 Vacuum hose schematic diagram
    148
  • 4 Senders and sensors
    150
  • 4.1 Removing and installing fuel temperature sender G81
    150
  • 5 Intake manifold
    151
  • 5.1 Assembly overview – intake manifold
    151
  • 5.2 Assembly overview – intake manifold flap
    151
  • 5.3 Assembly overview – intake manifold flap
    152
  • 6 Air filter
    154
  • 6.1 Assembly overview - air filter
    154
  • 7 Engine control unit
    155
  • 7.1 Removing and installing engine control unit
    155
  • Exhaust system
    157
  • 1 Exhaust pipes and silencers
    157
  • 1.1 Assembly overview – silencers
    157
  • 1.2 Assembly overview – silencers
    159
  • 1.3 Separating front and rear silencers
    160
  • 1.4 Installation position of clamps
    162
  • 1.5 Checking exhaust system for leaks
    162
  • 2 Emission control
    163
  • 2.1 Assembly overview - particulate filter
    163
  • 2.2 Removing and installing particulate filter
    165
  • 3 Exhaust gas temperature regulation
    173
  • 3.1 Removing and installing exhaust gas temperature sender 1 G235
    173
  • 3.2 Removing and installing exhaust gas temperature sender 2 G448
    174
  • 3.3 Removing and installing exhaust gas temperature sender 3 G495
    176
  • 4 Exhaust gas recirculation
    178
  • 4.1 Assembly overview – exhaust gas recirculation
    178
  • 4.2 Checking mechanical exhaust gas recirculation valve
    181
  • 4.3 Checking electronic exhaust gas recirculation valve
    182
  • Glow plug system
    184
  • 1 Glow plug system
    184
  • 1.1 Removing and installing glow plugs Q10/Q14
    184
  • 1.2 Checking glow plugs Q10/Q14
    186
  • 1.3 Removing and installing engine speed sender G28
    189
Manufacturer's designation 5-cylinder diesel engine
Manufacturer Volkswagen
Suitable for California / Multivan / Transporter / Transporter/Kombi LR (2003 - 2007) / Transporter (2003 - 2007)
Suitable car types 7H, 7J
Engine code BPC, AXD, AXE, BLJ
Category Reparaturanleitung

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