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Home » Manuals » 4-cyl. direct injection engine (1.5 l, 4V, EA211 EVO, turbocharger)
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  • Examplepage for repair manual 4-cyl. direct injection engine (1.5 l, 4V, EA211 EVO, turbocharger)
  • Examplepage for repair manual 2 4-cyl. direct injection engine (1.5 l, 4V, EA211 EVO, turbocharger)
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4-cyl. direct injection engine (1.5 l, 4V, EA211 EVO, turbocharger)

For Caddy

Original Volkswagen repair manual


26,43 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

35.032 KB

341 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger, Intake manifold and Lambda probe. Show more
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Repair manual Caddy 4-cyl. direct injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety regulations for working on fuel supply
    1
  • 1.2 Safety measures when working on vehicles with start/stop system
    2
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on ignition system
    2
  • 1.6 Safety precautions when working on exhaust system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 Repair instructions
    7
  • 3.1 Rules for cleanliness
    7
  • 3.2 General information
    7
  • 3.3 Foreign objects in engine
    7
  • 3.4 Contact corrosion
    8
  • 3.5 Routing and attachment of lines
    8
  • 3.6 Checking vacuum system
    8
  • Removing and installing engine
    10
  • 1 Removing and installing engine
    10
  • 1.1 Removing engine
    10
  • 1.2 Separating engine and gearbox
    18
  • 1.3 Securing engine on engine and gearbox support
    22
  • 1.4 Installing engine
    23
  • 2 Assembly mountings
    27
  • 2.1 Assembly overview – assembly mountings
    27
  • 2.2 Removing and installing engine mounting
    29
  • 2.3 Removing and installing gearbox mounting
    30
  • 2.4 Removing and installing pendulum support
    31
  • 2.5 Supporting engine in installation position
    32
  • 2.6 Adjusting assembly mountings
    37
  • 2.7 Checking adjustment of assembly mountings
    39
  • 3 Engine cover panel
    40
  • 3.1 Removing and installing engine cover
    40
  • Crankshaft group
    41
  • 1 Cylinder block (pulley end)
    41
  • 1.1 Assembly overview - cylinder block (pulley end)
    41
  • 1.2 Assembly overview - sealing flange, belt pulley end
    43
  • 1.3 Removing and installing poly-V belt
    43
  • 1.4 Removing and installing tensioner for poly V-belt
    44
  • 1.5 Removing and installing vibration damper
    45
  • 1.6 Removing and installing engine support
    46
  • 1.7 Renewing crankshaft oil seal - belt pulley end
    48
  • 1.8 Removing and installing sealing flange on pulley end
    51
  • 2 Cylinder block, gearbox end
    52
  • 2.1 Assembly overview - cylinder block, gearbox end
    52
  • 2.2 Removing and installing flywheel
    54
  • 2.3 Removing and installing sealing flange on gearbox side
    56
  • 2.4 Removing and installing adapter plate
    67
  • 2.5 Removing and installing intermediate plate
    68
  • 3 Crankshaft
    69
  • 3.1 Renewing needle bearing in crankshaft
    69
  • 3.2 Crankshaft dimensions
    71
  • 3.3 Measuring axial clearance of crankshaft
    71
  • 4 Pistons and conrods
    74
  • 4.1 Assembly overview - pistons and conrods
    74
  • 4.2 Removing and installing pistons
    77
  • 4.3 Checking pistons and cylinder bores
    79
  • 4.4 Separating new conrod
    82
  • 4.5 Checking radial clearance of conrods
    82
  • 4.6 Removing and installing oil spray jets
    83
  • 4.7 Setting piston to TDC position
    84
  • Cylinder head, valve gear
    87
  • 1 Cylinder head
    87
  • 1.1 Assembly overview - cylinder head
    87
  • 1.2 Assembly overview - camshaft housing
    88
  • 1.3 Removing and installing cylinder head
    91
  • 1.4 Removing and installing camshaft housing
    95
  • 1.5 Checking compression
    98
  • 2 Toothed belt drive
    101
  • 2.1 Assembly overview - toothed belt cover
    101
  • 2.2 Assembly overview - toothed belt
    101
  • 2.3 Removing and installing toothed belt guard
    103
  • 2.4 Removing and installing toothed belt
    105
  • 2.5 Checking valve timing
    108
  • 2.6 Preassembling and installing valve timing tool
    111
  • 2.7 Adjusting valve timing
    120
  • 2.8 Removing toothed belt from camshaft
    130
  • 3 Valve gear
    133
  • 3.1 Assembly overview - valve gear
    133
  • 3.2 Removing and installing camshaft oil seal
    135
  • 3.3 Removing and installing camshaft adjuster
    142
  • 3.4 Removing and installing cam actuator N583/N587/N591/N595
    150
  • 3.5 Removing and installing exhaust camshaft control valve 1 N318
    152
  • 3.6 Removing and installing valve stem seals
    153
  • 3.7 Removing and installing holder for oil seal
    159
  • 3.8 Checking control valve
    162
  • 3.9 Removing and installing oil seal on holder
    162
  • 3.10 Removing and installing inlet camshaft control valve 1 N727
    164
  • 4 Inlet and exhaust valves
    166
  • 4.1 Checking valve guides
    166
  • 4.2 Checking valves
    167
  • 4.3 Valve dimensions
    167
  • Lubrication
    168
  • 1 Sump, oil pump
    168
  • 1.1 Assembly overview - sump/oil pump
    168
  • 1.2 Engine oil:
    171
  • 1.3 Removing and installing oil sump
    171
  • 1.4 Removing and installing oil pump
    173
  • 1.5 Removing and installing oil level and oil temperature sender G266
    175
  • 2 Engine oil cooler
    177
  • 2.1 Assembly overview - engine oil cooler
    177
  • 2.2 Removing and installing engine oil cooler
    177
  • 3 Crankcase ventilation
    179
  • 3.1 Assembly overview - crankcase breather system
    179
  • 3.2 Removing and installing oil separator
    180
  • 4 Oil filter, oil pressure switch
    184
  • 4.1 Assembly overview - oil pressure switches/oil pressure control
    184
  • 4.2 Removing and installing oil pressure sender G10
    184
  • 4.3 Checking oil pressure and oil pressure switch
    186
  • 4.4 Removing and installing oil pressure regulating valve N428
    186
  • 5 Oil circuit
    188
  • 5.1 Assembly overview - oil circuit
    188
  • 5.2 Removing and installing oil supply line
    190
  • 5.3 Removing and installing oil return line for turbocharger
    191
  • Cooling
    193
  • 1 Cooling system/coolant
    193
  • 1.1 Connection diagram - coolant hoses
    193
  • 1.2 Checking cooling system for leaks
    195
  • 1.3 Draining and adding coolant
    197
  • 2 Coolant pump, regulation of cooling system
    205
  • 2.1 Assembly overview - coolant pump, thermostat
    205
  • 2.2 Assembly overview - electric coolant pump
    206
  • 2.3 Assembly overview - coolant temperature sender
    207
  • 2.4 Removing and installing charge air cooling pump V188
    208
  • 2.5 Checking coolant pump
    210
  • 2.6 Removing and installing coolant pump
    212
  • 2.7 Removing and installing toothed belt for coolant pump
    216
  • 2.8 Removing and installing toothed belt pulley for coolant pump
    216
  • 2.9 Removing and installing coolant temperature sender G62
    219
  • 2.10 Removing and installing engine outlet coolant temperature sender G82
    220
  • 2.11 Removing and installing radiator outlet coolant temperature sender G83
    221
  • 2.12 Removing and installing engine temperature regulation module GX33
    223
  • 3 Coolant pipes
    226
  • 3.1 Assembly overview - coolant pipes
    226
  • 3.2 Removing and installing coolant pipes
    227
  • 4 Radiator, radiator fan
    238
  • 4.1 Assembly overview - radiator, radiator fan
    238
  • 4.2 Assembly overview – radiator cowl and radiator fan
    240
  • 4.3 Removing and installing radiator
    240
  • 4.4 Removing and installing cooler for charge air cooling circuit
    242
  • 4.5 Removing and installing radiator cowl
    244
  • 4.6 Removing and installing radiator fan VX57
    245
  • 4.7 Removing and installing radiator fan 2 V177
    246
  • Turbocharging/supercharging
    248
  • 1 Turbocharger
    248
  • 1.1 Assembly overview - turbocharger
    248
  • 1.2 Removing and installing turbocharger
    250
  • 1.3 Removing and installing connection for turbocharger
    254
  • 1.4 Removing and installing charge pressure control module GX34
    255
  • 2 Charge air system
    257
  • 2.1 Assembly overview - charge air system
    257
  • 2.2 Checking charge air cooler for leaks
    259
  • 2.3 Removing and installing charge air cooler
    264
  • 2.4 Removing and installing charge pressure sender GX26
    266
  • 2.5 Checking charge air system for leaks
    267
  • 2.6 Removing and installing air intake pipe
    270
  • Mixture preparation - injection
    271
  • 1 Injectors
    271
  • 1.1 Assembly overview - fuel rail with injectors
    271
  • 1.2 Removing and installing fuel rail
    272
  • 1.3 Removing and installing injectors
    274
  • 1.4 Cleaning injectors
    278
  • 2 Air filter
    281
  • 2.1 Assembly overview - air filter housing
    281
  • 2.2 Removing and installing air filter housing
    283
  • 2.3 Removing and installing air guide on lock carrier
    283
  • 3 Intake manifold
    285
  • 3.1 Assembly overview – intake manifold
    285
  • 3.2 Removing and installing intake manifold
    287
  • 3.3 Cleaning throttle valve module GX3
    290
  • 3.4 Removing and installing throttle valve module GX3
    290
  • 3.5 Removing and installing intake connecting pipe
    292
  • 4 Senders and sensors
    294
  • 4.1 Removing and installing fuel pressure sender G247
    294
  • 4.2 Checking fuel pressure sender G247
    295
  • 4.3 Removing and installing intake manifold sender GX9
    296
  • 4.4 Removing and installing exhaust gas pressure sensor 1 G450
    297
  • 4.5 Removing and installing air mass measurement module GX35
    299
  • 5 Engine control unit
    300
  • 5.1 Removing and installing engine control unit J623
    300
  • 6 High-pressure pump
    301
  • 6.1 Assembly overview - high-pressure pump
    301
  • 6.2 Removing and installing high-pressure pump
    302
  • 6.3 Removing and installing high-pressure pipe
    303
  • 7 Lambda probe
    305
  • 7.1 Assembly overview - Lambda probe
    305
  • 7.2 Removing and installing Lambda probe 1 before catalytic converter GX10
    305
  • 7.3 Removing and installing Lambda probe 1 after catalytic converter GX7
    307
  • Exhaust system
    310
  • 1 Exhaust pipes and silencers
    310
  • 1.1 Assembly overview – silencers
    310
  • 1.2 Separating exhaust pipes from silencers
    312
  • 1.3 Removing and installing front silencer
    313
  • 1.4 Removing and installing centre silencer
    314
  • 1.5 Removing and installing rear silencer
    315
  • 1.6 Aligning exhaust system free of stress
    316
  • 1.7 Checking exhaust system for leaks
    317
  • 1.8 Installation position of clamp
    318
  • 2 Emission control
    319
  • 2.1 Assembly overview – emission control
    319
  • 2.2 Removing and installing catalytic converter
    321
  • 2.3 Removing and installing particulate filter
    324
  • Ignition system
    325
  • 1 Ignition system
    325
  • 1.1 Assembly overview - ignition system
    325
  • 1.2 Removing and installing ignition coils
    327
  • 1.3 Removing and installing knock sensor 1 G61
    329
  • 1.4 Removing and installing engine speed sender G28
    330
  • 1.5 Removing and installing inlet camshaft position sender G1002
    331
  • 1.6 Removing and installing exhaust camshaft position sender G1003
    332
Manufacturer's designation 4-cyl. direct injection engine (1.5 l, 4V, EA211 EVO, turbocharger)
Manufacturer Volkswagen
Suitable for Caddy (2021 >)
Suitable car types SB
Engine code DPBC
Category Reparaturanleitung

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