Service Workshop Manual Transporter 2004 > Edition 03.2018 Service Department. Technical InformationService List of Workshop Manual Repair Groups Repair Group 00 - Technical data 10 - Removing and installing engine 13 - Crankshaft group 15 - Cylinder head, valve gear 17- Lubrication 19 - Cooling 24 - Mixture preparation - injection 26 - Exhaust system 28 - Ignition system Technical information should always be available to the fore careful and constant adherence to the instructions is essential t. safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a matter of course, be observed. All rights reserved. No reproduction without prior agreement from publisher. Copyright © 2018 Volkswagen AG, Wolfsburg k005898232000 - Technical data 10 13 15 1 14 2 24 22 23 3 a4 4 44 5 Bt Removing and installing engine 1 14 12 13 2 24 Transporter 2004 > 6-cylinder injection engine - Euition 03.2018 Contents Identification. Engine number/engine data Safety information Safety precautions when working on the cooling system Safety regulations for working on fuel supply Safety precautions when working on ignition system Repair instructions. Rules for cleanliness when working on fuel supply systenvinjection system General information .. General notes on ignition system Technical data... .. ss sveeveeeeeeees Technical data- injection system Removing and installing engine Removing engine Securing engine on engine and gearbox support VAS 6095 Installing engine ‘Assembly mountings. Overview - assembly mountings Crankshaft QrOUp oe eee eee eee eeeeeeeu sete eeeueeeueeeenes 1 14 12 13 2 24 22 23 3 34 32 4 44 42 43 44 Cylinder head, valve gear 1 14 12 13 14 2 24 22 3 34 Cylinder block (pulley end) Assembly overview - cylinder block Removing and installing poly-V belt Renewing crankshaft oil seal - belt pulley end Cylinder block, gearbox end : Assembly overview - cylinder block, gearbox end Renewing crankshaft oil seal (gearbox end) Removing and installing drive plate Crankshaft. Assembly overview - crankshaft Removing and installing sender wheel Pistons and conrods : Assembly overview - pistons and conrods Checking pistons and cylinder bores Installing piston Piston and cytinder dimensions Cylinder head .. Assembly overview - cylinder head Removing and installing cylinder head Removing and installing cylinder head cover Checking compression Cover for timing chain. Assembly overview - timing chain cover Installing cover seals Chain drive... Assembly overview - timing chain ContentsTransporter 2004 > 6-cylinder injection engine - Edition 03.2018 3.2 Checking valve timing 58 3.3 Adjusting valve timing 59 4 Valve gear ... . . . eee eee e eee. 66 4.4 Assembly overview - valve gear 66 4.2 Measuring axial pay of camshaft 69 4.3. Removing and instaling camshatts 69 4.4 Removing and instaling valve stem seals 75 5 Inlet and exhaust valves - wee eteeee ee wee . .. 78 5.1 Checking valve guides 78 5.2 Reworking valve seats 78 5.3 Valve dimensions 80 17 - Lubrication beeeeee ceeeees . 81 1 Sump, oll pump at 4.4 Assembly overview- sump/oll pump at 1.2 Assembly overview- oll pump ea 4.3 Removing and instaling oll sump 86 44 Measuring oil consumption 87 15 Engine oil 88 2 Oil filter, oil pressure switch 89 2.4 Assembly overview- oll fiter housing, oll pressure switch 89 2.2 Checking oil pressure and oil pressure switch 90 19 - Cooling : 93 1 Cooling systemvcoolant : . . . . eves eter ees 9 4.4 Fitting location overview - cooling system 93 4.2 Overview of fiting locations - coolant hoses 96 4.3 Connection diagram - coolant hoses 96 4-4 Draining and adding coolant 97 4.5 Checking cooling system for leaks 104 2 ‘Coolant pump, regulation of cooling system ..... . bree . wees 106 2.4 Assembly overview - thermostat 106 2.2 Removing and instaling coolant pump 107 3 Radiator, radiator fan. . settee tenes veeeeee ees 109 3.4 Assembly overview - radiator 109 3.2 Assembly overview radiator cowl and radiator fan V7 110 3.3 Removing and instaling radiator 12 24 - Mixture preparation - injection ...... 60: 0cceseeeveeeeeeeeeeseeeeen eee MB 4 Vacuum system .... : . ee 15, 1.41 Assembly overview- vacuum system 115 2 Injectors. sees ceeeeeeees 116 2.1 Removing and instaling injactors 116 2.2 Checking injectors "7 3 ‘Senders and sensors . sees eee eeeeeee ees 121 3.4 Checking fuel pressure regulator and holding pressure 121 4 Intake manifold boeeeteceeeeeeres 124 4.4 Assembly overview - intake manifold 124 4.2 Exploded view- fuel rail 125 5 Air filter. Peer eee eee 127 5.1 Assembly overview ~airfiter 127 6 Engine (motor) control unit .......---..00seee eee nee wees 128 6.1. Removing and instaling engine (motor) control unit J623 128 ContentsTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 26 - Exhaust system .... 1 14 12 2 24 22 23 3 a4 32 33 28- Ignition system . 1 14 12 13 Exhaust gas cleaning . Assembly overview - emission control Removing and installing exhaust pipe/catalytic converter Exhaust pipes and silencers Assembly overview - silencers Separating exhaust pipes from silencers Aligning exhaust system free of stress ‘Secondary air system .. Assembly overview - secondaty air system Function Checking combination valve Ignition system . Assembly overview - ignition system Removing and installing ignition coils with output stage Test data, spark plugs .129 129 129 130 133 133 134 136 136 136 137 137 =. 140 . 140 140 141 143 ContentsTransporter 2004 > 6-cylinder injection engine - Edition 03.2018 iV. contentsTransporter 2004 > finder injection engine - Edition 03.2018 Technical data 1 Identification (VRLO11498; Eaition 03.2018) 21.1 Engine number/engine data, page 1 1.1 Engine number/engine data The engine number (‘engine code” and “serial number") is located next to the vibration damper on the cylinder block. The engine number consists of up to nine characters (alphanu- meric). The first part (maximum 3 characters) makes up the engine code, and the second part (6 characters), the serial num- ber. If more than 999,999 engines were produced with the same code letters, the first of the six digits is replaced by a letter. Additionally, a sticker with “engine code" and “serial number" is bonded onto the intake manifold The engine code is also included on the vehicle data sticker |Engine code BDL BKK Manufactured 08.03 06.03» cylinder arrangement FR? FRO cylinder angle 15.0° 15.0° Displacement q 32 32 Power KW at rpm| 173/620 173/620 Frorque Nm at pm 3186/2950 315/2960 Bore Diameter, mm 84.0 84.0 [stroke mm] 95.9 95.9 Valves per cylinder 4 4 [Compression ratio 11.25 10.85 RON rin, 98 unleaded?! 98 unleaded?) /System designation Motronic ME7.1.1 Motronic ME7.1.1 Firing order 15-36-24 1-5-8-6-2-4 Knock control 2 knock sensors 2 knock sensors Lambda regulation 4 probes 4 probes [catalytic converter yes yes Exhaust gas recirculation No No Jcharging No No JSecondary air system yes yes Electronic power control yes yes Variable intake manifold yes yes Jcamshatt timing adjustment Yes Yes’! Leakage diagnosis system No No 4)VR= Veatrangementin compactintine design 2) In exceptional circumstances min. 95 RON, however with reduced perform 3) Two independently variable camshafts ‘identification 412 Safety information 22.1 Safety precautions when working on the cooling system’ page 2 32°2.2 Safety requlations for working on fuel supply’, page 2 22.3 Safety precautions when working on ignition s) 21 Safety precautions when working on the cooling system A Caution ‘Observe the following points during all installation work, in par- ticular in the engine compartment, due to the space limitations: Route all the various lines (e.g. for fuel, hydraulics, acti- vated charcoal fiter system, coolant and refrigerant, brake Fadl and vacuum) afd loch weg th Bak orghalpe- sitions. Ensure that there is sufficient clearance to all moving or ‘hot components. Note + Cooling system is pressurized when engine is warm. Ifnec- essary, release pressure before carrying out repairs. # Hose connections are secured with spring-type clips. Incase of repair, only use spring-type clips. © Hose clip pliers - VAS 6340- are recommended to install Spring-type clips. © When installing coolant hoses, route stress-free so that they do not come into contact with other components (observe markings on coolant connection and hose) Test for leaks in cooling system using cooling system tester - VAG 1274- and adapters VAG 1274/8- and-VAG 1274/9- 22 Safety regulations for working on fuel supply @ Note # Hose connections are secured with couplings or spring-type or clamp-type clips. # Always renew crimp-type clips with spring-type clips. # Fuel hoses on engine must be secured with spring-type clips only. The use of crimp-type or screw-type clips is not permis- sible, © Hose clip pliers - VAS 6340- are recommended to install Spring-type clips. 2 Rep. gr00-Technical data6-cylinder injection engine - Euition 03.2018 A Caution Observe the following points during all installation work, in Iaadar tothe engine Sempariment dae the apace inlalons: Route all the various lines (e.g. for fuel, hydraulics, acti- vated charcoal fiter system, coolant and refrigerant, brake Auld and vacuum) and electrical wing in ther eiginalpo- 8. ¢ Ensure that there is sufficient clearance to all moving or ‘hot components. When removing and installing fuel gauge sender or fuel pump (fuel delivery unit) from a full or partly full fuel tank, observe the following: To prevent injuries to persons and/or damage to the injection and ignition system, the following must be observed: Switch off ignition before connecting or disconnecting injection and ignition system wiring as well as test instrument cables. Note the following if testers and measuring instruments have to be used during a road test Test and measuring instruments must always be secured to rear seat and operated by a second person from this location Iftest and measuring instruments are operated from front pas- senger seat and the Vehicle Is involved in an accident, there is a possibility that the person sitting in this seat may receive serious Injuries when the airbag Is triggered. © Ifthe engine is to be turned at starter speed without starting: = Pull connector off ignition coils with output stage for cylinders A WARNING. Fue system ig under pressure! Wear protective and protective clothing to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose ‘connections. Then release pressure by carefully pulling hose off connection. Even before work starts, the extraction hose of a fume extrac- tion system which is switched on must be placed in the vicinity ofthe assembly opening of the fuel tank to extract any escap- ing fumes. If no exhaust gas extraction system is available, a radial fan with a displacement greater than 16 m°m can be used providing that motor is not in air flow. Prevent skin contact with fuel! Wear fuel-resistant gloves! ¢ For safety reasons, fuses SD14 and SD30 must be removed from fuse holder before fuel system is opened because fuel pump can be activated by door contact switch in driver door. Fuses SD14 and SD30 -arrows- are located in electronics box fuse holder in engine compartment. Transporter 2004 > 2.Satety information 3Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 23 Safety precautions when working on ig- nition system To prevent injuries to persons and/or damage to the injection and ignition system, the following must be observed: Switch offignition before connecting or disconnecting injection and ignition system wiring as well as test instrument cables, # Do nottouch or disconnect ignition cables when the engine Is. running or being tured at starter speed. Note the following if testers and measuring instruments have to be used during a road test. Test and measuring instruments must aWvays be secured to rear seat and operated by a second person from this location. Iftest and measuring instruments are operated from front pas- senger seat and the vehicle is involved in an accident, there is a possibility that the person sitting in this seat may receive serious Injuries when the airbag is triggered. Ifthe engine is to be turned at starter speed without starting = Pull connector off ignition coils 1...6 using assembly tool - THott8- — Fit assembly tool - T10118- on locking mechanism button -arrow- and carefully pull connector off fe Neh Ged! eo Trove A rep. 91.00-Technical dateTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 3 Repair instructions 23.1 Rules for cleanliness when working on fuel su tem! injection system", page 5 3.1 Rules for cleanliness when working on fuel supply system/injection system When working on the fuel supply/injection system, carefully follow the °S rules" below: Thoroughly clean all joints and surrounding areas before dis- mantiing Place removed parts on a clean surface and cover them over. Use lintfree cloths only. + Carefuly cover opened components or seal them i repairs cannot Be carried out immediately. ¢ Install only clean parts; do not remove new parts from pack- aging until immediately before installing. Do notuse parts that have been kept unpackaged (for example in toolboxes). © If system is open: do not use compressed alr if possible. Try not to move the vehicle, 3.Repairinstuctions 5Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 4 General information 2 ‘4.1 General notes on ignition system", page 6 41 General notes on ignition system General notes on ignition system # Only the components which specifically relate to the ignition system are dealt with here. For other components of the in- jection and ignition system, = page 115 For trouble-free operation of electrical components, a voltage of at least 11.6 Vis necessary. + Certain tests may lead toa fault being detected by te contol unit and stored. Therefore, after completing all the checks and repaits, read the event memory and clear itif necessary = Ve- hicle diagnostic tester. © Rep. gr00-Technical dataTransporter 2004 > finder injection engine - Edition 03.2018 5 Technical data 25.1 Technical data - injection system’, page 7 51 Technical data - injection system [Engine code ating check Idling speed! [Engine (motor) control unit System designation Part number Governed speed BDL/BKK ‘pm 650...750 Motronic ME7.1.1 = Parts programme tpm| From approx. 6500 4) Not adjustable 5.Technical data 7Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 10 Removing and installing e1 1 Removing and installing engine 21.1 Removing engine", page 8 21.2 Securing engine on engine and gearbox support VAS 6095, = page 13 2 “1.3 Installing engine”, page 14 14 Removing engine Special tools and workshop ‘equipment required a a VAG 1306 VAG 1931 VAG 1332 VAG 13834 QS —_) + Lifting tackle - 3083 # Engine support- 3395- © Drip tray- VAG 1306- discontinued, use drip tray for work- shop hoist- VAS 6208- # Torque wrench - VAG 1331- @ Torque wrench - VAG 1382- B Rep. gr:10-Removing and instaling engine6-cylinder injection engine - Euition 03.2018 Engine and gearbox jack - V.A.G 1383 A- discontinued, use engine and gearbox jack - VAS 6931- VAS 5024 A, a Transporter 2004 > VAS 5085 fr VAS 6095 — SEP ey jwi0 190°9 © Spring-type clip pliers - VAS 6024 A- discontinued, use hose clip pliers - VAS 6340- Ladder - VAS 6086- discontinued, use steps- VAS 6292/4- Engine and gearbox support- VAS 6095- Workshop hoist - VAS 6100- ‘Adapter -710261- Not illustrated: . . . . Container for removed parts - V.AG 1698- # Grease - G 000 100- (vehicles with manual gearbox) © Cable tie 41. Removing and instaling engine Q@ Note The engine is removed downwards with gearbox. ¢ Allcable ties which are opened or cut through when engine is removed must be replaced in the same position when engine is installed. @ Leave ignition key in ignition lock to prevent steering lock from engaging. + itis advisable to remove the front wheels before beginning engine removal. The vehicle can then be lowered on the lifting platform untl the splash plates for the brake discs are just ‘above the floor. This provides the most ergonomic working position regarding accessibility of engine compartment com- ponents. Some components cannot be removed, or removed only with ‘ificulty, with the engine installed. Therefore, you should de- termine all defective components before removing engine and renew them while engine is removed. + Toprevent damage to removed components, place therm in the’ container for removed parts - VAG 1698 — With the ignition switched off, disconnect battery earth strap. — Remove noise insulation + General body repairs, exterior, Rep. gt. 66 ; Exterior equipment, Noise insulation = Bring lock cartier into service position = General body repairs, exterior; Rep. gr. 50; Body- front, Lock carrier A WARNING Hot steam may escape when expansion tank is opened. Wear protective goggles and clothing to avoid eye injuries and scald- ‘ing. Cover cap with a cloth and carefully open. (Open and close expansion tank cap to release pressure in cooling system. Drain coolant = page 97 Remove coolant expansion tank Pull off radiator coolant hoses from engine A WARNING Fuel: lines are under sure! Wear e} ion and yesupp tne rund rosie! ea aye tector and the connection before loosening hose connections. Then re- lease pressure by carefully pulling hose off connection. 10 ep. 9110- Removing and instalng engine— Pull off supply line -3- and return line -2- (with blue marking) and catch fuel that leaks out with a cloth. — Pull off breather hose -1- (with white mark). [nae To do this, press down release button on hose coupling. — Seal ines so that fuel system is not contaminated by dirt Observe rules for cleanliness = page § — Separate connectors from the following components: (E) Note Before removing connectors, mark each connector and compo- nent to which it belongs. # Coolant temperature sender - G62- Continued cootant circulation pump - VE1- Inlet camshaft control valve 1 - N208- Exhaust camshaft control valve 1 -N318- Hall sender - G40- Hall sender 2- G163- Injector cylinder no. 4...6 -N30...N33, N83, NB4~ Engine speed sender - G26- Knock sensor | - G61- Knock sensor Il - G66- ll level and oil temperature sender - G266- Pull vacuum hose off brake servo = Disconnect all electrical wiring from gearbox, alternator and starter and lay to side — Pull off or disconnect all other electrical connections as nec- essary from engine and lay to side — Separate all connections, coolant and vacuum hoses and lines from engine, — Remove connecting pipe between throttle valve module - J338- and air filter. — Remove poly V-belt = page 19 — Unbolt power-assisted steering vane pump from ancillaries bracket and putto one side, hoses remain connected: + Run- ning gear, axles, steering, Rep. gr. 48, Vane pump — Remove air conditioning compressor from ancillary bracket, and secure itto one side so that the refrigerant pipes and ho- ses are not stressed = Heating, all conditioning, Rep. gt. 87; Airconditioning compressor — Remove alternator: + Electrical system; Rep. gt. 27 ; Alter- nator — Remove ancillary bracket from cylinder block = Item 30 (page 19) finder injection engine - Edition 03.2018 Transporter 2004 > 4. Removing and instaing engine 11— Remove front exhaust pipe with catalytic converter = page 129 Vehicles with manual gearbox — Unbolt selector mechanism from gearbox + Rep. gr. 34; Selector mechanism — Remove hydraulic clutch slave cylinder+ Rep. gr. 30; Clutch mechanism Vehicles with automatic gearbox — Remove selector lever cable from gearbox: = Rep. gt. 37 Continued for all vehicles = Disconnect drive shafts from gearbox = Running gear, axles, steering; Rep. gr. 40; Removing and installing drive shafts — Fitadapter - 710261- on cental bolt of rear torque reaction support as shown, and unscrew torque reaction support from the engine mounting — Remove subframe + Running gear, axles, steering; Rep. gr 40; Assembly overview - subframe’ — Insertengine bracket-3396-in engine and gearbox jack- VAS 6931 — Fitengine support- 3396- onto cylinder block and tighten se- curing nuts -1- to 40 Nm. fi Note Mtnecessary, shorten threads of pin by approx. 1 mm. — Raise engine and gearbox slightly using engine and gearbox Jack - VAS 6931- — Unscrew securing bolts -arrows- of engine mounting, @ Note To remove securing bolts, use steps - VAS 6292/4- 710261 VAG 1331 12 Rep. 9140- Removing and instalng engine6-cylinder injection engine - Euition 03.2018 Transporter 2004 > — Unscrew securing bolts for gearbox mounting -arrows- — Carefully lower assembly. (A) Note Engine and gearbox must be guided carefully when lowering to prevent daniage to the bodywork. 1.2 Securing engine on engine and gearbox support - VAS 6095- ‘Secure engine to engine and gearbox support - VAS 6095- to carry out repairs. ‘Sequence of operations = Unbolt gearbox. Vehicles with automatic gearbox — Secure torque converter against “falling out’ after separating engine from gearbox. Continued for all vehicles — Attach lifting tackle - 3033- with auxiliary hook - 10-222 A/2- as follows and lift engine out of engine and gearbox jack - VAS 6931- using workshop hoist-VAS 6100- Vibration damper end: position 3. Flywheel end: position 11, — Secure engine on engine and gearbox support- VAS 6095- Additional information and assembly work for vehicles with air conditioner (A) Note To prevent damage to condenser, refrigerant lines or hoses, en- sure that lines and hoses are not stretched, kinked or bent, — Remove retaining clamp(s) for reftigerant lines, — Remove air conditioner compressor > Heating, air condition- ing system, Rep. gr. 87 VAS 6095, 4. Removing and instaing engine 13,1.3 Installing engine Install in reverse order of removal, observing the following A Caution Observe the following points during all installation work, in par- feular in the engine compartment duo to the space imitations: ¢ Route all the various lines (0.9. for fuel, hydraulics, acti- vated charcoal ter system, coolant and refrigerant, brake {uid and vacuum) and electrical wiring in their original po- sitions. Ensure that there is sufficient clearance to all moving or ‘hot components. — Check whether dowel sleeves for centring engine and gearbox are in cylinder block and install if necessary. — When installing engine and gearbox, ensure that there is su ficient clearance to drive shafts. Specified torques for assembly mountings = page 16 Vehicles with manual gearbox Check clutch release bearing for wear, and renewifnecessary = Rep. gr. 30 Lightly grease clutch release bearing, release bearing guide sleeve and splines on input shaft with G 000 100. Install hydraulic clutch slave cylinder + Rep. gr. 30; Clutch mechanism Install selector mechanism, and adjust cables if necessary = Rep. gt. 34 ; Selector mechanism Vehicles with automatic gearbox — Install selector lever cable to gearbox + Rep. gt. 37 Continued for all vehicles = Electrical connections and routing: + Electrical system; Rep. gr. a7 Install ancillaries bracket and alternator: + Electrical system; Rep. gt. 27; Removing and installing alternator Install air conditioner compressor = Heating, air conditioning system; Rep. gr. 87 ; Air conditioning compressor Install vane pump for power assisted steering + Running gear, axles, steering; Rep. gr. 48; Vane pump Install poly V-belt + page 19 Install drive shafts: + Running gear, axles, steering; Rep. gr 40; Removing and installing drive shafts Install subframe + Running gear, axles, steering; Rep. gf. 40; Assembly overview - subframe 14. ep. 9110- Removing and instalng engine— Fitadapter-T10261- on central bolt of torque reaction support {as shown, and tighten torque reaction support on the engine ‘mounting. — Install front exhaust pipe with catalyt = page 129 — Install noise insulation + General body repairs, exterior, Rep. gt. 66 ; Exterior equipment, Noise insulation — Add coolant = page 97 — Adapt engine control unit to throttle valve module, carry out a road test, and read event memory = Vehicle diagnostic tester. Specified torques nverter [Bolted connection [Specified torque| [Nuts and bolts Mé 40Nm MZ 415.Nm Ma 25.Nm Mio 40.Nm Miz 60 Nm 22.1 Overview - assembly mountings", page 16 2 "1.1 Assembly overview - emission control, page 129 22.1 Assembly overview - silencers", page 133 2 "1.1 Assembly overview - cylinder block’, page 17, Transporter 2004 > finder injection engine - Edition 03.2018 710261 VAG 1331 4. Removing and instaing engine 15,Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 2 Assembly mountings 22.1 Overview - assembly mountings", page 16 21 Overview - assembly mountings Engine mounting Specified torques ‘Component ‘Specified torque Botts A 50 Nm +90° Bots 8-7 90 Nm +90" Bolts -C-7 50 Nm +90" 5) Renew bots Gearbox mounting Spesified torques ‘Component ‘Specified torque Bots A 50 Nm +90" Bots 8-7 50 Nm +90" 6) Renew bots Rear torque reaction support Specified torques ‘Component ‘Specified torque Bolts A) 50 Nm +90° Botta 50 Nm +90" Bolts -C-7 20 Nm +90" 7) Renew bots Front torque reaction support Spesified torques. ‘Component ‘Specified torque Bolts A) 25. Nm Bolts 8-7 25.Nm Bolt-c-9 90. Nm +160" Bolts -D-7 20 Nm +90" 8) Renew bots 16 ep. 9110 Removing and instalng engineTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 1 Cylinder block (pulley end) 21.1 Assembly overview - cylinder block’, page 17 1.2 Removing and installing poly-V belt’, page 19 2 “1.3 Renewing crankshaft oil seal - belt pulley end’, page 20 14 Assembly overview - cylinder block (F) naw © Secure engine on engine and gearbox support- VAS 6095- to ‘arty out repairs. Finding metal shavings or a large quantity of small metal par- icles during engine repair could inaicate that the crankshaft bearings of conrod bearings are damaged. To prevent this from causing further damage, perform the following repairs: Thoroughly clean oll channels. Renew oll non-return valve. Renew oll spray jets. Renew engine oll cooler. Renewing oil fiter 4. Cylinder block (pulley end) 17Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 1-Bolt Q 45Nm 2 Engine support 3-Bolt Q Secured to intake mant fold, Q 5Nm 4- Oil dipstick Q The oillevel mustnotbe above the max. mark! Markings = page 88 5 - Guide tube Q For ail dipstick. Q Secured with bolt to in- take manifold 6 - Cylinder block Removing and installing crankshaft = page 27 Q Dismanting and assem- bling pistons and con- rods = page 29 7 - Knock sensor 1 - G61- Q Fitting location: be- ‘tween cylinder 1 and cylinder 3 8- Bolt Q The specified torque in fluences the function of the knock sensor. 20Nm 9- Bott QO 10Nm 10 - Oll pump drive cover 11- O-ring Q Renew after removal Lubricate before assembling. 12- ll pump drive 43 - Oil non-return valve Q Observe installation position OQ Clean if badly soiled Q Observe notes = page 17 Q_ Removing and installing = page 84 14- Intermediate shaft 15 - Thrust washer 16 - Bolt 10Nm 17- Knock sensor Il - GE6- Fitting location: between cylinder 4 and cylinder 6 18 rep. g113-crankshat group6-cylinder injection engine - Euition 03.2018 Transporter 2004 > 18- Input shaft For oil pump drive. 19- Oil pump Dismantling and assembling > page 64 20 - Bolt 0 25Nm 24 - Oil drain plug Q Ifsealis leaking, nip open and renew. Q 30Nm 22- Oil pan Removing and installing = page 86 23 - Oil level and oll temperature sender - G266- 24- Bolt 0 12Nm 25 - Bolt O 25Nm 26 - Torque reaction support OQ Front 27 - Bolt 0 25Nm 28 - Fitted bolt 0 25Nm 29- Bolt O 20Nm 30 - Ancillary bracket 31 - Vibration damper 32- Bolt O Renew after removal D100 Nm+g0° 33 - Engine speed sender - G28- 34- Seal To loosen and tighten securing bolt, secure vibration damper us- ing counterhold = T10069- fi Note @ Renew securing bolt for vibration damper. Tighten securing bolt using torque wrench - VAG 160- 1.2 Removing and installing poly-V belt ‘Special tools and workshop equipment required 4. Cylinder block (pulley ena) 19Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 # M&x50 hexagon bolt Removing — Remove engine cover panel. — Remove noise insulation + General body repairs, exterior, Rep. gt. 66 ; Exterior equipment, Noise insulation = Bring lock cartier into service position = General body repairs, exterior, Rep. gr. 50; Body- front, Lock carrier = Mark poly V-belt direction of rotation. — Screw M8x60 bolt into threaded hole -arrow- of tensioning roller until poly V-belt is slack. = Remove poly V-bett Installing Install in reverse order of removal, observing the following: fi Note % Before installing poly V-belt, ensure that all ancillary assem blies (alternator, air conditioner compressor, vane pump) are secured tightly. © Check that faler roller turns easily. ¢ When fitting the poly V-belt observe belt direction of rotation and that the belt is seated correctly in the belt pulleys, = Install poly V-belt and remove M8 bolt from tensioning roller. Poly V-belt routing with air conditioner compressor: After completing repairs aways: = Start engine and check belt running 13 Renewing crankshaft oil seal - belt pulley end 20 Rep. g113- crankshaft groupTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 Special tools and workshop ‘equipment required 720143 wt 10215, J \ 2 6b so ( = We Ts ee a T1069 T1059 V.AG 1601 V.AG 1382 wta.s0007 Extractor hook -720143/1- Counter-hold tool - T10069- # Insert tool -710215- # Torque wrench-V.AG 1601- # Torque wrench - V.AG 1332- Removing — Remove poly V-belt = page 19 — Remove vibration damper. To do this, lock vibration damper using countethold - T10069- — Fitpuller hooks - 1201 43/1- behind sealing lip of oll seal as shown in illustration Tro08s a 4. Cylinder block (pulley ena) 24Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 — Support puller hook -T20143/1- on sealing flange and lever seal out in direction of -arrow. Installing Install in reverse order of removal, observing the following Remove oil residue from crankshaft journal using clean cloth. Slide quide sleeve -T10215/1 journal Now slide oll seal possible onto front of crankshaft - carefully over guide sleeve as far as Press oil seal in to stop with fitting sleeve - T10216/2--3-. To do this, use an old vibration damper securing bolt-4~ fi Note + . Renew securing bolt for vibration damper. Tighten securing bolt using torque wrench - VAG 1601- Install vibration damper and lock with counterhold - T10069- Tighten new securing bolts Install poly V-belt > page 19 Specified torques @ 21.1 Assembly overview cylinder block”, page 17 Tro08s a 22 Rep. g113- Crankshaft groupTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 2 Cylinder block, gearbox end 22.1 Assembly overview - cylinder block, gearbox end’, page 23 = ‘2.2 Renewing crankshaft oll seal (aearbox end)", page 24 22.3 Removing and installing drive plate", page 25 241 Assembly overview - cylinder block, gearbox end 1-Bolt O Renew after removal © To loosen and tighten, use counterhold- 710069- = page 20 D100 Nm+90° 2.- Vibration damper 3- Bolt 0 10Nm 4- Seal O Renewing = page 20 5 - Sealing flange O Coat sealing surfaces with sealant - AMV 176 501- 6 - Cylinder block Removing and insaling crankshat = page 27 1. Dismantiing and assem- bling pistons and con- rods = page 29 7 - Sealing flange O Coat sealing surfaces with sealant - AMV 176 501- 8- Seal Remove using extractor hook - T20143/2- PTFE oll seal a Identification: Without inner hose spring. a a Do not additionally oil or grease the oil seal sealing lip Before installing, remove oil residue from crankshaft journal using a clean cloth Q Installing * page 24 9- Dual-mass flywheel! 10 - Bolt Renew after removal Q To loosen and tighten, use counterold - T10044- (with 5 mm spacers) or counterhold - T10068- O 60Nm+90° 11 Bolt Q 25Nm 2.Cyfinder block, gearbox end 236-cylinder injection engine - Edition 03.2018 2.2 Renewing crankshaft oil seal (gearbox end) Special tools and workshop equipment required Fitting tool-T10122- # Extractor hook -720143- Removing = Fitpuller hooks - 7201 43/2- behind sealing lip of oll seal as shown in illustration. — Support puller hook -T20143/2- on sealing flange and lever seal out in direction of -arrow. Installing Install in reverse order of removal, observing the following: T20143 an 24 rep. g113- Crankshaft groupTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 — Pull seal-A-with the outer side over the sleeve -T10122/1- of fitting tool - 101 22- onto pulling sleeve - T10122/2- — Separate the two fitting sleeves. — Then set pulling sleeve -T10122/2- with dry oll seal onto crankshaft journal. — Now drive itinto sealing flange to stop using thrust piece - T10122/3- 2.3 Removing and installing drive plate Special tools and workshop equipment required Counter-hold tool - T10069- 1006s 2. Cylinder block, gearbox end 25,Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 @ Torque wrench - VAG 1332- Removing — Remove drive plate. To do this, lock vibration damper using counterhold -T10069- — Loosen drive plate securing bolts diagonally and remove. — Remove drive plate Installing Install in reverse order of removal, observing the following: Fit drive plate on crankshaft Insert at least 3 old securing bolts and tighten to 30 Nm. = Check dimension -a- through the three holes for securing the torque converter using a straightedge and depth gauge and calculate average. — Compare average with specification (measured distance + thickness of straight edge). Specification: 16.7 to 17.3 mm. If specification is not attained: — Remove drive plate again and fit appropriate shim -1- fi Note Only one shim of the appropriate thickness may be used for com- pensation. When specification is attained: — Insert new securing bolts and tighten by hand. = Tighten securing bolts (turning further can be done in several steps), Specified torques @ 2°2.1 Assembly overview. a iinder block, gearbox end’, page VAG 1892 26 ep. 9113- crankshaft groupTransporter 2004 > finder injection engine - Edition 03.2018 3 Crankshaft 213.1 Assembly overview - crankshaft’, page 27 ‘3.2 Removing and installing sender wheel", page 28 31 Assembly overview - crankshaft @ Note ¢ Before removing crankshaft make provision for a suitable sur- face for storing crankshaft to ensure that sender whee! = Item 6 (page 28) 1s not damaged or lies against any other item. © Secure engine on engine and gearbox support- VAS 6095- to ‘arty out repairs. ¢ When changing bearing shells, use only bearing shells of same colour code. 1- Bearing cap Bearing cap 1: vibration damper end Bearing cap § with re- cesses for thrust wash- ers Bearing shell retaining lugs in cylinder block and bearing caps must align. 2- Bolt Renew after removal O30 Nm+130° 2x 90° further is permit- ted. 3- Bearing shells 1...7 Forbearing cap without oil groove, For cylinder block with oil groove OQ Do notinterchange used bearing shells (mark). 4 Thrust washer Forbearing cap 5 Note fixing arrangement 5 - Crankshaft Before removing, see notes = page 27 Axial clearance new: 0.07...0.23 mm; wear limit: 0.30 mm O Check radial clearance with Plastigage. New: 0.02...0.06 mm, wear limit: 0.10 mm, Q Do not rotate crankshaft when checking radial clearance a.crankehat 27Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 Q Crankshaft dimensions, crankshaft bearing: 59.958...69.978 mm, conrod bearing: §3.958...63.978 mm. Reworking is not permitted 6 - Sender wheel Q Renew after removal Q For engine speed sender - G28- Q Installing = page 28 7-Bolt Q Renew after removal Q 10Nm+90° 8- Oll spray jet Q For crankshaft bearings 2 to 7 Q For piston cooling Opening pressure: 2.0 bar Removing and installing = page 83 1 Observe notes = page 17 3.2 Removing and installing sender wheel ‘Special tools and workshop equipment required # Torque wrench - VAG 1331- V.A.G 1331 Locking fluid - D 000 6000 A2- ‘Sequence of operations Ensure that contact surfaces of crankshaft and sender wheel are free of oll and grease. — Lightly coat contact surfaces of crankshaft and sender wheel with locking fluid - D 000 600 A2- for additional security. — Ensure during installation that marking -VR6--arrow- is post tioned over single threaded hole. — First tighten all new securing botts lightly by hand. — First, tighten securing bott-1- — Then, tighten securing botts -2- Specified torques @ 23.1 Assembly overview - crankshaft, page 27 28 Rep. g113- Crankshaft groupTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 4 Pistons and conrods 24.1 Assembly overview - pistons and conrods”, page 29 "4.2 Checking pistons and eylinder bores’, page 31 24.3 Installing piston", page 32 2 "4.4 Piston and cylinder dimensions”, page 33 44 Assembly overview - pistons and conrods 1 - Piston rings Q Offset gaps by 120° Q_ Use piston ring pliers to remove and instal, "TOP" faces towards piston crown Checking ring gap = page St Checking ring-to-groove clearance = page 31 2- Piston Q Checking = page 31 Mark cylinder number and installation position relative to conrod. Low point of piston crown faces to centre of cylinder block Instaling piston p39 3 - Retaining ring 4 Connecting rod Renew as set only. Mark cylinder number ae instalation position: marks -A- must be above one another. 5 - Bearing shell Observe installation po- sition _ Q Do notinterchange [wis 40 used bearing shells. The lugs on bearing shells must ft tightly in the recesses. O Axial clearance new: 0.06...0.31 mm, wear limit: 0.40 mm Check radial clearance using Plastigage: new: 0.02...0.07 mm, wear limit: 0.10 mm. Do not turn crank- shaft when measuring radial clearance 6 - Conrod bearing cap a a Mark cylinder number -B- Installation position: marks -A- must be above one another. 7- Bolt a a Renew after removal ll threads and contact surface 4. Pistons and contods. 29)Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 Q To measure radial clearance, tighten to 30 Nm but not further. 30.Nm+30° 8 - Cylinder block Q Checking cylinder bores = page 31 Q_ Removing and installing crankshaft = page 27 Q Piston and cylinder dimensions = page 33 9- Piston pin faitficutt to remove, heat piston to 60°C. Remove and install using drift- VW 222 A- Allocation of crankshaft bearing shells (classification) Main bearing shells of the correct thickness are allocated to the cylinder block and crankshaft at the factory. Coloured dots are sed to identity the thickness of the bearing shells. Ifthe cylinder block or crankshaft is changed, the crankshaft bearing shells must be reallocated Always insert bearing shell for cylinder block (upper bearing shell) with yellow colour marking Establish the correct colour marking for the bearing shell in the bearing cap (lower bearing shell) using the letters on the cylinder block and the crankshaft. The firstletter is allocated to bearing cap one, the secondto bear- ing cap two, ete Cylinder block identification The letters can be found on the sealing surface of the sump. Crankshaft identification The letters are located on the outer crank web of No. 1 cylinder. — Note letters and identity colour code to be installed based on table. 30 ep. g113- crankshaft group6-cylinder injection engine - Euition 03.2018 Transporter 2004 > Letter on cylinder block |Letter on crankshaft web [Colour marking of bearing | Colour marking of bearing shell for bearing cap ___|shell for cylinder block AB COE R red [yellow AB.CDE ic red lyellow A6.C,D.E B yellow lyellow ABCDE Vv biue [yellow GH IR red yellow HI 6 red [yellow HI B yellow [yellow HI Vv [biue yellow KLM F red lyellow KLM ie yellow lyellow KLM B blue [yellow KLM Vv [Motet [yellow Example Bearing cap 1 2 3 4 5 é 7 Letters on cylinder block is H Hi Hi 6 E 6 Letters on crankshaft web iS 5 B Vv B B 6 [Colour marking of bearing shell red [yellow yellow blue [yellow |yelow [red tor bearing cap 42 Checking pistons and cylinder bores Checking piston ring gap ‘Special tools and workshop equipment required @ Feeler gauge Test sequence — Push ring at right angles to cylinder wall from above down to approx. 15 mm from bottom end of cylinder. Push in using 2 piston without rings Piston ring Ring gap New Wear limit Rectangular-section ring _mm| 0.20..0.40 io Tapered stepped ring __mm| 0.20...0.40 10 [Oil scraper ring mm| 0.26...0.60 10 Checking ring-to-groove clearance ‘Special tools and workshop equipment required © Feeler gauge 4. Pistons and conrods 31Clean annular groove before check. Piston ring Clearance New. Wear limit Rectangular-section ring __mm| 0.04...0.09 0.15 [Tapered stepped ring mm _0.08...0.06 0.15 [Oil scraper ring mm|_0.02...0.06 0.15 ‘Special tools and workshop equipment required © External micrometer 75 to 100 mm Checking piston Measure pistons approx 6 mm fram the lower edge of skirt, at 90° to the piston pin axis. Deviation from nominal dimension: max. 0.04 mm, Checking cylinder bores Special tools and workshop equipment required Internal dial test indicator 0...100 mm Test sequence # Take measurements at 3 positions in both lateral direction -A- and longitudinal direction -B-. # Deviation from nominal dimension: max. 0.08 mm @ Note The cylinder bores mustnotbe measured when the cylinder block is mounted on assembly stand, as measurements may then be incorrect 43 Installing piston Special tools and workshop equipment required 32 Rep. g113- crankshaft groupTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 ro 2. BD ARE Piston fitting tool -110147- fi Note Ifa new piston fitting too! is used to install the pistons, first pass piston with oed piston rings tice through the tool and rernove ‘any resulting metal shavings, ifnecessary. Only then install piston with piston rings. ‘Sequence of operations — Push piston into oiled piston fitting tool-110147- by hand. Low point of piston crown must face lug on the piston fiting tool -arrows, Hold piston fiting tool-T101.47- (with piston inserted) on upper edge and press piston in with both thumbs. Push piston in until itprotrudes approx. 15 mm from the lower ‘edge of the piston fitting tool Place piston in respective cylinder bore. Lug on piston fitting tool -arrow- must face centre of cylinder block. Hold fiting too! tightly against cylinder block and push piston in. 44 Piston and cylinder dimensions Honing dimen- Piston @ | Cylinder bore @ sion [Basic dimension mm] 83.965 84.010 4. Pistons and contods. 33,Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 ie; 1 Cylinder head 21.1 Assembly overview - cylinder head”, page 34 211.2 Removing and installing cylinder head", page 38 inder head, valve ge: 2 “1.3 Removing and installing cylinder head cover’, page 45 21.4 Checking compression’, page 48 141 Assembly overview - cylinder head fi Note fan exchange cylinder head is installed, all the contact sur- faces between the supporting elements, roller rocker fingers and the running surfaces of the camshafts must be olled be- fore the cylinder head cover is installed. © The plastic protectors fitted to protect the open valves must be removed only immediately before the cylinder head is fitted. © When renewing the cylinder head or cylinder head gasket drain all the off coolant and refil with new coolant. 34 ep. 9115 cylinder head, valve gearTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 1- Cylinder head cover 2-Bolt © With spacer sleeve and seal O Renew seal if damaged 0 10Nm 3- Oring O Renew if damaged © Lubricate before as- sembiing. a For ignition coil with out- put stage, 4- Bracket 5-Bolt Q 10Nm 6-Cap Renew sealif damaged 7- Oil filer neck 8 - Spreader rivet, 9- Nut Q 10Nm 10 - Spacer sleeve and seal Renew seal if damaged 11 Bolt | / Q 23Nm “ f({ 12- Bracket For connector for knock sensor 1 - G61- 35 34 32 33 92 28 SS 31 5 30 29 28 27 26 24 a0] 18 - Lifting eye 14- Camshaft timing chain Before removing, mark direction of rotation (installation position) = page 58 15 - Inlet camshaft control valve 1 - N205- Q For inlet camshaft Q Before removing, mark connector belonging to component, 16 - Exhaust camshaft control valve 1 - N318- Q For exhaust camshaft Q._Before removing, mark connector belonging to component, 177 - Bracket Q For wiring harness 18 - O-ring Renew after removal Q For sealing oil channel O Lubricate before assembling, 19 - Hall sender 2 - G163- Q For exhaust camshaft Q._Before removing, mark connector belonging to component, 1. cylinder head 35Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 20 - Chain tensioner Q For camshaft timing chain = Item 14 (page 95 Q Only rotate engine when chain tensioner is installed 40Nm 21 - Seal Renew if damaged or leaking 22-Nut 10Nm 23 - Bracket Q For wiring harness and earth connection. Q For Lambda probe after catalytic converter - G130- 24 - Bolt QO 8Nm 25- Seal © For camshaft control valve 1 - N206- = Item 15 (page 36) and exhaust camshaft control valve 1 - N318- = Item 16 (page 35 Renew if damaged or leaking O Instaling = page 63 26 - Bracket 27 - Thermostat housing Q Dismanting and assembling = page 106 © Connection diagram for coolant hoses = page 96 28 - Seal Renew after removal 29 - Hall sender - G40- Q For inlet camshaft Q Before removing, mark connector belonging to component. 30 - Cover section Q Can be removed and installed with engine installed. Ifonly cover has been removed, prepare cylinder head gasket for assembly = page 54 31 - Bracket 32 - Bolt Q Renew after removal Q Contact surface of sender wheel must be dry around bolt head when installed Q To remove and install counterhold with 32 mm open-end spanner on camshaft = page 69 60.Nm+a0° 33 - Exhaust camshaft adjuster Q Identification: 324, © Rotate engine only with camshaft adjuster installed. O Instaling = page 59 34 - Slide rail Q For camshaft timing chain = Item 14 (page 95 © Clipped into valve timing housing 35- Inlet camshaft adjuster Q Identification: 24 © Rotate engine only with camshaft adjuster installed. O Instaling = page 59 36 ep. 9115- cylinder head, valve gearTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 36 - Cylinder head gasket Q Renew after removal Metal gasket. Q Preparing cylinder head gasket for assembly = page 64 Q After renewing, renew entire coolant. 37 - Cylinder head Q Check for distortion = page 37 Q Removing and installing = page 38 Q After renewing, renew entire coolant. 38 - Tensioning element Q For poly V-belt. Removing and installing poly V-belt = page 19 39- Cylinder head bolt Renew after removal Q Follow installation instructions and sequence when loosening and tightening = page 38 40 - Gasket for cylinder head cover Renew if damaged or leaking Q Observe installation position Checking cylinder head for distortion ‘Special tools and workshop equipment required © Straight edge © Feeler gauge Max. permissible distortion: 0.05 mm. 1.cylinder head 3712 Removing and installing cylinder head Special tools and workshop equipment required Ti0068 A. V.A.G 1306 V.A.G 1331 V.A.G 1332 VAS 5024 A Tio095 A, ————" SS wis 10010 # Camshaftbar-110068 A © Drip tray- VAG 1306- discontinued, use drip tray for work- shop hoist- VAS 6208- # Torque wrench - VAG 1331- @ Torque wrench - VAG 1332- # Spring-type clip pliers - VAS 024 A- discontinued, use hose clip pliers - VAS 6340- Puller-T10095 A- # Contour blade set- VAS 852 005- (not illustrated) or commer cially available CERAN surface scraper 38 Rep. 9115 cylinder head, vate gearRemoving A Caution (Observe the following points during all installation work, in par- {cular in the engine compartment, due to the space limitations: Route all the various lines (e.g. for fuel, hydraulics, acti- vated charcoal iter system, coolant and refrigerant, brake fufd and vacuum) and electrical wing inter orginal po- ¢ Ensure that there is sufficient clearance to all moving or ‘hot components. ) Note The battery earth must be disconnected for the remaining pro- cedure. Therefore, frst check whether a coded radio is hited, Then obtain anti-theft coding first Ifnecessary. ¢ Allcable ties which are opened or cut open when engine is removed must be replaced in the same position when engine Is installed. ¢ Some components cannot be removed, of removed only with ‘ifficulty, with the engine installed. Therefore, you should de- termine all defective components before removing engine and renew them while engine is removed. © To prevent damage to removed components, place them in the container for removed parts - V.AG 1698- — With ignition switched off, disconnect battery earth strap — Remove noise insulation + General body repairs, exterior; Rep. gr. 66; Exterior equipment, Noise insulation — Remove front exhaust pipe with catalytic converter = page 129 — Bring lock cartier into service position + General body repairs, exterior, Rep. gr. 50; Body-front, Lock carrier A WARNING Hot steam may escape when expansion tank is opened. Wear protective goggles and clothing to avoid eye injuries and scald- ‘ing. Cover cap with a cloth and carefully open. — Open and close expansion tank cap to release pressure in cooling system. = Drain coolant + page 97 — Remove coolant expansion tank, — Remove thermostat housing = page 106 finder injection engine - Edition 03.2018 Transporter 2004 > 1.cylinder head 39A WARNING Fuel system is under pressure! Wear protective goggles and protective clothing to avoid injury and contact with the skin. Wrap a cloth around the connection before loosening hose connections. Then release pressure by carefully pulling hese off connection. — Pull off supply line -3- and return line ~ and catch fuel that leaks out with a cloth. = Pull off breather hose -1- (with white mark). (a) Note To do this, press down release button on hose coupling (with blue marking) — Seal lines so that fuel system is not contaminated by dirt Observe rules for cleanliness = page § — Remove intake manifold = page 45 — Separate connectors from the following components: @ Note Before removing connectors, mark each connector and compo- nent to which it belongs, # Coolant temperature sender - G62- # Continued coolant circulation pump - V51- 4 Injector cylinder no. 1...6 - N30...N33, N83, N84 = Pull connectors off Hall sender - G40- -1- and Hall sender 2 - G163--2- = Pull connectors off camshaft control valve 1 - N205--3- and exhaust camshaft control vaive 1 - N318-~4-. @ Note Before removing connectors, mark each connector and compo- nent to which it belongs, — Pull off/disconnect all further wiring necessary from cylinder head and move clear. = Separate all connections, coolantand vacuum hoses and lines from cylinder head — Remove poly V-belt = page 19 AO rep. or 15-cyiinder head, vane gear— Set crankshaft to TDC marking of No. 1 cylinder -arrow- by turning crankshaft at vibration damper securing bolt in direc- tion of engine rotation — Remove cylinder head cover = page 45 — Remove chain tensioner for camshaft timing chain -arrow- — Now unscrew cover securing bolts-arrows- and remove cover. — Mark camshaft timing chain before removing (e.g. with paint/ coloured mark, arrow pointing in direction of rotation). fi Note Do not mark chain with a centre punch mark, notch or any similar means! — First remove exhaust camshaft adjuster. finder injection engine - Edition 03.2018 Transporter 2004 > t.cytngerheaa 41— Remove camshaft adjuster together with camshaft timing chain from intake camshaft fi Note Counterhold only with 32 mm open-end spanner -arrow- on cam- shaft. The camshaft bar -T10068 A- must not be fitted when camshaft adjuster Is loosened or tightened. — Remove securing bolts -arrows- and remove guide rail -1-. — Lay camshaft timing chain aside. — Loosen cylinder head bolts in the sequence given starting at the outside and working inwards and then remove completely. — Carefully remove cylinder head with the assistance of a 2nd mechanic, = Check cylinder head for distortion = page 37 42 rep. or 15- cylinder head, vane gearfinder injection engine - Edition 03.2018 Transporter 2004 > Installing Install in reverse order of removal, observing the following (A) Note ¢ Do notuse sandpaper, grinding wheels, abrasive or scour pads or any other sanding or abrasive media. © Sealing surface (see photo) must not project Discolouration (dark spots, see photo) need not be removed. ¢ When removing the sealant residue, make sure no loose par- ticles get into the open channels of the engine. © Ensure that all adjacent workspaces are clean, and that none of the above mentioned sanding or abrasive media are used. ¢ Using unauthorised sanding or abrasive media may lead to secondary damage such as, for example, damage to the tur- bocharger or the conrod bearings. ZL\ _ warnine Wear protective goggles. — Do notuse any other means rather than the contour blade set = VAS 852 005- or a commercially available CERAN surface ‘scraper to remove the sealant residue from the cylinder head and cylinder block + The sealing surfaces must not be damaged. + There must be no oll or coolant n the bolt packets, + Do notremove new cylinder head gasket from packaging until itis ready to be fitted + If anew cylinder head is installed, contact surfaces between roller rocker fingers and running surface of cam must be oiled — Remove any loose remains using a lintfree cloth. Ifthe piston for No. 1 cylinder is not at TDC. — Set crankshaftto TDC marking of No. 1 cylinder -arrow- by ‘turning crankshaft at vibration damper securing bolt in direc- tion of engine rotation. At the same time, have @ second mechanic guide camshaft timing chain by hand — Fitnew cylinder head gasket Inscription (Part No.) must be readable. 1.cylinder hea 43Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 Ensure that dowel sleeves are inserted into cylinder block holes 12 and 20, and that cylinder head gasket is located Position camshafts in cylinder head to TDC No. 1 cylinder. Camshaft bar -T10068 A- must engage in grooves in both shafts Now prepare cylinder head gasket for assembly = page 64 Fitcylinder head, screw in new cylinder head bolts and tighten hand tight. fi Note The longer eyindsr head bolts must be inserted in the centre holes of cylinder head. = Tighten cylinder head bolts in tightening sequence shown working from inside to outside: Pretighten botts to 30 Nm Tighten botts to 50 Nm 3- Turn bolts 90° further using rigid wrench. 4- Turn bolts another 90° further using rigid wrench (Fi) ro © Ensure that the O-ring for sealing the oll channel and the seal are fitted in the cover. + Itisnotnecessary to retighten cylinder head bolts after repairs. — Adjust vaive timing + page 59 — Install cylinder head cover and intake manifold = page 45, Fill with new coolant = page 97 Specified torques @ 21.1 Assembly overview cylinder head", page 34 @ 22.1 Assembly overview timing chain cover", page 52 @ 24.1 Assembly overview - intake manifold, page 124 AA rep. ot 15- cylinder head, vane gear13 Removing and installing cylinder head cover (CF) no This procedure also describes removal of the intake manifold. Transporter 2004 > 6-cylinder injection engine - Euition 03.2018 Special tools and workshop equipment required VAS 5024 A A oe VAG 1331 rroue a pease dh er Qe’ T1005 A. jovis 19020 © Spring-type clip pliers - VAS 6024 A- discontinued, use hose clip pliers - VAS 6340- # Torque wrench-V.AG 1331- # Assembly tool-T10118- # Puller-T10095 A- Removing — With the ignition switched off, disconnect battery earth strap. — Allcable ties which are opened or cut open when engine is removed must be replaced in the same position when engine is installed. — Remove engin ver panel t.cylinder hea 45Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 = Bring lock cartier into service position = General body repairs, exterior; Rep. gr. 50; Body- front, Lock carrier = Detach 6-pin connector from throttle valve module - J338- -arrow-. — Remove intake hose -1- from between air mass meter - G70- and throttle valve module - J338- = Pull connector -1- off intake manifold flap changeover valve - N230- = Pull U-hose -2- off T-piece = Pull connector offignition coils using assembly tool-T10118- = Unclip wiring harness and move to side A WARNING Hot steam may escape when expansion tanks opened. Wear protective goggles and clothing to avoid eye injuries and scald- ‘ing. Cover cap with a cloth and carefully open. — Open and close expansion tank cap to release pressure in cooling system. — Pull coolant hoses-1- off throttle valve control unit- J338- and seal hose ends, AG rep. or 15- cylinder head, vane gearTransporter 2004 > finder injection engine - Edition 03.2018 — Now pull hose -1- off intake manifold. — Pull off vacuum hose to brake servo ~ = Pull off vacuum lines -1~ — Remove crankcase breather hose -: = Unscrew bolt from intake manifold support = Unscrew bolt from intake manifold support — Unclip all hoses and components from bracket-1- 1.cylinder head 47Transporter 2004 > 6-cylinder injection engine - Edition 03.2018 — Fitpuller-110095 A- from fiat side of connector in direction of arrow and pull out ignition coil with output stage (cyl. 1 6). = Unscrew dipstick guide tube -1- = Unscrew securing bolts -arrows- for intake manifold and re- move intake manifold from cylinder head. (F) ro ‘Seal intake ports in intake manifold and in cytinder head with a lean cloth. — Pull off or disconnect all other electrical connections from cy inder head cover as necessary and lay to one side. — Remove cylinder head cover. Installing Install in reverse order of removal, observing the following: fi Note @ Renew cylinder head cover if damaged or leaking. © Bolt intake manifold fst to cylinder head. Then tighten the two bolts of intake manifold support # Ensure fuel hoses are seated correctly. — Ifnecessary fill with coolant > page 97 Specified torques @ 21.1 Assembly overview cylinder head", page 34 14 Checking compression 710035 A AB rep. or 15- cylinder head, vane gearTransporter 2004 > 6-cylinder injection engine - Euition 03.2018 Special tools and workshop equipment required an28 T10095 A & 8x Tote V.A.G 1381 jwviss © Spark plug socket- 3122 © Puller-T10095 A @ Assembly tool-T10118 # Torque wrench-V.AG 1331- # Compression tester - V.AG 1763- Prerequisites for check + Engine oll temperature at least 30°C + Battery voltage must be atleast 11.5 V. + Allelectrical consumers, e.g. lights and rear window heating, must be switched off + Ifthe vehicle is equipped with an air conditioner, it must be switched of. + Onvehicles with automatic gearbox the selector lever must be in "P* or “N* position, Test sequence — Remove engine cover panel. — Pull connectors offignition coils 1...6. Assembly tool-T10118- can be used to release connector catches, 1.cylinder head 49