X Tuned Automotive , +27785245692

181 Golden Poppy Crescent , Crossmoor , eThekwini ,

eThekwini , 4092

Volkswagen Transporter T5
Technical specifications CFCA/2 (7H/7J/7E/7F) (04-15)

Vehicle identification

No. of cylinders Type 4/DOHC

Capacity cc 1968

Compression ratio :1 16,5

Fuel system Make Bosch

Fuel system Type EDC 17

Injection system

Injection system

Air metering Type Mass

Fuel/injection pump assembly Make Bosch

Pump type Common rail

Injection sequence 1-3-4-2

Fig75573

Injector nozzle Make Bosch

Tuning and emissions

Tuning and emissions

Idle speed rpm 860±100

Rated no load speed rpm 4700-5100

Oil temperature °C 80

Idle speed - for smoke test rpm 760-960

Governed speed range - for smoke test rpm 4700-5100

Maximum time at governed speed secs 2,0

Test mode A/B B

Probe type 1/2 1

Conditioning Accelerations/rp 10
m

Smoke opacity - homologation value m-1 (%) 0,50 (19) EU3/4=0,80 (29)

Starting and charging

Starting and charging

Battery V/RC(Ah) 12

Glow plugs

Glow plugs

Glow plug - part no. Original Beru/NGK

equipment

Glow plug - part no. Beru GE108

Glow plug - part no. NGK Y-609AS

Service checks and adjustments

Service checks and adjustments

Valve clearance - INLET mm Hydraulic

Valve clearance - EXHAUST mm Hydraulic

Compression pressure bar 19,0-31,0

Oil pressure bar/rpm

Idle speed = 0,6 bar min.

Above 2000 rpm = 5,0 bar max.

Radiator cap bar 1,40-1,60

Thermostat opens °C 75
Lubricants and capacities

Engine oil options

Ambient temperature range All temperatures

Engine oil grade SAE 5W-30

To VW specification 507.00
Low ash engine oil MUST be used to ensure long service life of diesel particulate filter (DPF).

Engine oil classification OEM VW 507.00

Engine with filter(s) litres 7,0

Other lubricants and capacities

Manual transmission oil grade SAE

Manual transmission oil

02Z transmission = G 052 512

0A5 transmission = G 052 171

Manual transmission litres 2,0 6sp=2,7

Auto shift manual (ASM) transmission oil grade SAE G 052 182

Auto shift manual (ASM) transmission (drain & refill) litres 6,0

Auto shift manual (ASM) transmission

0BT transmission

Connect diagnostic equipment and check ATF temperature is below 45°C before work is started.

Draining transmission

Renew transmission oil filter.

Ensure all auxiliary equipment is switched OFF.

Ensure ignition is switched OFF.

Remove level plug and level tube and allow ATF to drain.

Remove Mechatronic unit drain plug and allow ATF to drain.

Refit Mechatronic unit drain plug with new seal.

Refit level tube.

When replacing level tube ensure it is seated correctly.

Distance = 12,2-12,6 mm fig1192753.A

Do NOT start engine when ATF has been drained from transmission.

Filling transmission

Fill transmission with specified amount using VAS 6262.

Check ATF level and top up if necessary.
Fit level plug with new seal.
 Checking ATF level

Ensure transmission is not in emergency running mode. Do NOT start engine when little or no ATF is in the transmission.

Ensure selector lever in 'P'. Start engine.

Connect diagnostic equipment to check ATF temperature.

Ensure ATF temperature is 35°C.

Depress brake pedal. Select each gear for a minimum of 3 seconds, then return selector lever to 'P'.

Remove level plug and check level.

If ATF flows gently from level hole before the ATF temperature has reached 45°C, the level is OK.

When checking oil level disregard oil surge that occurs every 30 seconds due to clutch cooling.

If no fluid loss apparent: Top up until ATF flows gently from level hole.

Fit level plug with new seal.

Level plug must be refitted before temperature reaches 45°C.

fig1192753

Auto shift manual (ASM) transmission (dry fill) litres 7,4-7,6

Specified quantity for reference purposes only.

Transmission is filled for life. In case of repair, refer to drain and refill procedure.

Differential rear litres 1,1

Haldex = 1,0 litre

Transfer box oil grade SAE G 052 518

Transfer box litres 1,2

Coolant Type G12 Plus Plus

Coolant Colour Purple

Cooling system - total capacity litres 11,0

Brake fluid classification VW 501.14

Brake fluid litres 1,0-1,2

Clutch fluid classification VW 501.14

Power steering fluid Type G 004 000

Tightening torques
Tightening torques

Cylinder head instructions

Fig75880

Cylinder head

Renew bolts Yes

Tighten 35 Nm

Tighten 60 Nm

Tighten 90°

Tighten 90°

Other engine tightening torques

Sump drain bolt 30 Nm

Sump plug

Use new sump drain bolt

Flywheel/driveplate 60 Nm+90°

Use new bolts.

Clutch pressure plate 13 Nm M7=22 Nm

Crankshaft pulley/damper centre bolt 120 Nm+90°

Use new bolts.

Crankshaft pulley/damper bolts 10 Nm+90°

Use new bolts.

Camshaft sprocket/gear

A = 20 Nm + 45° (use new bolts)

 B = 100 Nm

fig79276

fig79276

Camshaft carrier/cap 1)5 Nm 2)10 Nm

Camshaft/rocker cover 10 Nm

Injector/clamp 8 Nm+270°

Injector to cylinder head/clamp

Injectors, injector pipes and clamps must always be refitted to the same cylinder if re-using.

Use new bolts.

Injector pipe unions 30 Nm

Fuel/injection pump sprocket/gear 95 Nm

Glow plugs 18 Nm

Engine oil pressure switch 22 Nm

Chassis tightening torques

Front hub

Use new nuts and tighten in the following stages:

1. 200 Nm
2. Slacken off 180°
3. 200 Nm

Rear hub

Use new nut.

4x4 = 200 Nm

Steering track rod end 60 Nm+90°

Use new nuts.

Brake disc to hub Front 15 Nm

 2FNR44 caliper (PR No. 2E4) = 20 Nm

Brake caliper to carrier Front 30 Nm

2FNR44 caliper (PR No. 2E4) = 60 Nm

Brake caliper/carrier to hub Front 180 Nm+45°

Use new bolts.

Brake disc to hub Rear 15 Nm

Brake caliper to carrier Rear

FN44 caliper (PR No. 0WR) = 30 Nm

FN3 caliper (PR No. 2E3/2E4):
Use new bolts.
35 Nm

Brake caliper/carrier to hub Rear 165 Nm

FN44 caliper (PR No. 0WR) = 180 Nm

ABS sensor Front 8 Nm

ABS sensor Rear 8 Nm

Road wheels 180 Nm

Do NOT lubricate bolts.

Lubricate mating surfaces between wheel centre hole and hub (use spray wax).

Brake disc and drum dimensions

Brake disc and drum dimensions

Minimum disc thickness for replacement - ventilated Front

FN3 caliper (PR No. 2E3) = 26,5 mm

FN3 caliper (PR No. 2E4) = 29,5 mm
2FNR44 caliper (PR No. 2E4) = 26,5 mm

Minimum disc thickness for replacement - ventilated Rear 19,5 mm

FN44 caliper (PR No. 0WR) = 18 mm

Minimum pad thickness Front 2 mm

Minimum pad thickness Rear 2 mm

Maximum drum diameter for replacement Rear 186 mm

Minimum shoe thickness Rear 1 mm

Parking brake travel No. of notches 5-7

Air conditioning

Air conditioning

No. of AC service connectors 2

Air conditioning restrictor type Expansion valve

Compressor clutch/magnetic coupling No

Compressor variable displacement solenoid Yes

Air conditioning refrigerant Type R134a

Air conditioning refrigerant quantity grams

→VIN 7H-A-050000, →VIN 7J-A-010000

Denso 7SEU16C/Sanden SD7V16 compressor = 650±50 grams

With second evaporator = 950±50 grams

VIN 7H-A-200001→, VIN 7J-A-200001→

Denso 6SEU14C/7SEU17C compressor = 525±25 grams

With second evaporator = 825±25 grams

Air conditioning oil Type

Denso compressor = G 052 300 A2

Sanden compressor = G 052 154 A2

Air conditioning oil quantity cm³

Denso compressor = 140±10 cm³

With second evaporator = 240±10 cm³
Sanden compressor = 135±15 cm³
With second evaporator = 235±15 cm³

Air conditioning oil viscosity ISO 46

©Copyright and database rights: Autodata Limited 1972-2025.