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  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 2 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
  • Examplepage for repair manual 3 4-cylinder common rail engine (2.0 l, 4V, turbocharger)

4-cylinder common rail engine (2.0 l, 4V, turbocharger)

For Caddy

Original Volkswagen repair manual


33,22 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

43.450 KB

453 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, Injectors/high-pressure accumulator (rail), Intake manifold, Lambda probe and SCR system (selective catalytic reduction). Show more
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Repair manual Caddy 4-cylinder common rail 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
    1
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on SCR system
    2
  • 1.6 Safety precautions when working on ignition system
    3
  • 1.7 Safety precautions when working on exhaust system
    3
  • 2 Identification
    5
  • 2.1 Engine number/engine data
    5
  • 3 Repair notes
    7
  • 3.1 Rules for cleanliness
    7
  • 3.2 General information
    7
  • 3.3 General repair instructions
    8
  • 3.4 Foreign objects in engine
    8
  • 3.5 Contact corrosion
    8
  • 3.6 Routing and attachment of lines
    9
  • 3.7 Fitting radiators and condensers
    9
  • 3.8 Checking vacuum system
    9
  • 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
    30
  • 2.3 Removing and installing gearbox mounting
    32
  • 2.4 Removing and installing pendulum support
    33
  • 2.5 Supporting engine in installation position
    34
  • 2.6 Adjusting assembly mountings
    37
  • 2.7 Checking adjustment of assembly mountings
    40
  • 3 Engine cover panel
    42
  • 3.1 Removing and installing engine cover
    42
  • Crankshaft group
    43
  • 1 Cylinder block (pulley end)
    43
  • 1.1 Assembly overview - cylinder block (pulley end)
    43
  • 1.2 Assembly overview - sealing flange, belt pulley end
    45
  • 1.3 Removing and installing poly-V belt
    47
  • 1.4 Removing and installing tensioner for poly V-belt
    49
  • 1.5 Removing and installing vibration damper
    49
  • 1.6 Removing and installing bracket for ancillaries
    50
  • 1.7 Removing and installing engine support
    52
  • 1.8 Removing and installing sealing flange on pulley end
    53
  • 2 Cylinder block, gearbox end
    56
  • 2.1 Assembly overview - cylinder block, gearbox end
    56
  • 2.2 Removing and installing flywheel
    57
  • 2.3 Removing and installing sealing flange on gearbox side
    59
  • 3 Crankshaft
    70
  • 3.1 Assembly overview - crankshaft
    70
  • 3.2 Crankshaft dimensions
    72
  • 3.3 Renewing needle bearing in crankshaft
    72
  • 3.4 Measuring axial clearance of crankshaft
    74
  • 3.5 Measuring radial clearance of crankshaft
    75
  • 4 Pistons and conrods
    76
  • 4.1 Assembly overview - pistons and conrods
    76
  • 4.2 Removing and installing pistons
    79
  • 4.3 Measuring piston projection at TDC
    80
  • 4.4 Checking pistons and cylinder bores
    82
  • 4.5 Separating new conrod
    85
  • 4.6 Checking radial clearance of conrods
    85
  • 4.7 Removing and installing oil spray jets
    86
  • Cylinder head, valve gear
    88
  • 1 Cylinder head
    88
  • 1.1 Assembly overview - cylinder head
    88
  • 1.2 Assembly overview - camshaft housing
    91
  • 1.3 Assembly overview - cylinder head cover
    91
  • 1.4 Removing and installing cylinder head
    93
  • 1.5 Removing and installing cylinder head cover
    100
  • 1.6 Removing and installing injector seals
    102
  • 1.7 Removing and installing camshaft housing
    104
  • 1.8 Checking compression
    110
  • 2 Toothed belt drive
    112
  • 2.1 Assembly overview - toothed belt cover
    112
  • 2.2 Assembly overview - toothed belt
    112
  • 2.3 Removing and installing toothed belt guard
    114
  • 2.4 Removing and installing toothed belt
    119
  • 2.5 Removing toothed belt from camshaft
    132
  • 3 Valve gear
    137
  • 3.1 Assembly overview - valve gear
    137
  • 3.2 Measuring axial play of camshaft
    141
  • 3.3 Removing and installing camshaft oil seal
    142
  • 3.4 Removing and installing camshaft adjuster
    144
  • 3.5 Checking hydraulic compensation elements
    147
  • 3.6 Removing and installing valve stem seals
    148
  • 4 Inlet and exhaust valves
    158
  • 4.1 Checking valve guides
    158
  • 4.2 Checking valves
    159
  • 4.3 Valve dimensions
    159
  • Lubrication
    160
  • 1 Sump, oil pump
    160
  • 1.1 Assembly overview - sump/oil pump
    160
  • 1.2 Engine oil
    163
  • 1.3 Removing and installing oil sump
    163
  • 1.4 Removing and installing oil pump
    165
  • 1.5 Removing and installing oil level and oil temperature sender G266
    167
  • 2 Engine oil cooler
    169
  • 3 Oil filter, oil pressure switch
    170
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    170
  • 3.2 Removing and installing oil pressure switch F1
    172
  • 3.3 Removing and installing oil pressure switch for reduced oil pressure F378
    174
  • 3.4 Checking oil pressure
    176
  • 3.5 Removing and installing oil filter housing
    176
  • 3.6 Removing and installing oil pressure regulating valve N428
    179
  • 4 Oil circuit
    181
  • 4.1 Removing and installing oil supply line
    181
  • 4.2 Removing and installing oil return line for turbocharger
    184
  • Cooling
    187
  • 1 Cooling system/coolant
    187
  • 1.1 Connection diagram - coolant hoses
    187
  • 1.2 Draining and adding coolant
    191
  • 1.3 Checking cooling system for leaks
    197
  • 2 Coolant pump, regulation of cooling system
    200
  • 2.1 Assembly overview - coolant pump, thermostat
    200
  • 2.2 Assembly overview - coolant temperature sender
    204
  • 2.3 Assembly overview - electric coolant pump
    204
  • 2.4 Removing and installing coolant pump
    205
  • 2.5 Removing and installing charge air cooling pump V188
    206
  • 2.6 Removing and installing auxiliary pump for heating V488
    208
  • 2.7 Removing and installing thermostat
    210
  • 2.8 Checking thermostat
    214
  • 2.9 Removing and installing coolant temperature sender G62
    214
  • 2.10 Removing and installing coolant valve for cylinder head N489
    216
  • 3 Coolant pipes
    217
  • 3.1 Assembly overview - coolant pipes
    217
  • 3.2 Removing and installing coolant pipes
    219
  • 4 Radiator, radiator fan
    233
  • 4.1 Assembly overview - radiator/radiator fan
    233
  • 4.2 Assembly overview – radiator cowl and radiator fan
    235
  • 4.3 Removing and installing radiator
    235
  • 4.4 Removing and installing radiator cowl with radiator fan
    237
  • 4.5 Removing and installing radiator fan VX57
    238
  • 4.6 Removing and installing radiator fan 2 V177
    239
  • 4.7 Removing and installing auxiliary radiator
    240
  • Turbocharging/supercharging
    244
  • 1 Turbocharger
    244
  • 1.1 Assembly overview - turbocharger
    244
  • 1.2 Removing and installing turbocharger
    250
  • 1.3 Renewing vacuum unit for turbocharger
    256
  • 1.4 Removing and installing connection for turbocharger
    259
  • 1.5 Removing and installing pulsation damper
    261
  • 2 Charge air system
    263
  • 2.1 Assembly overview - charge air system
    263
  • 2.2 Removing and installing charge air cooler
    263
  • 2.3 Removing and installing charge pressure sender G31
    263
  • 2.4 Checking charge air system for leaks
    264
  • 2.5 Removing and installing charge air pipe
    266
  • Mixture preparation - injection
    267
  • 1 Injection system
    267
  • 1.1 Schematic overview - fuel system
    267
  • 1.2 Filling/bleeding fuel system
    268
  • 1.3 Checking fuel system for leaks
    269
  • 2 Vacuum system
    270
  • 2.1 Connection diagram – vacuum system
    270
  • 3 Injectors/high-pressure accumulator (rail)
    271
  • 3.1 Assembly overview - injectors
    271
  • 3.2 Assembly overview - fuel rail
    273
  • 3.3 Adapting correction values for injectors
    274
  • 3.4 Checking return flow rate of injectors with engine running
    276
  • 3.5 Checking return flow rate of injectors at starter speed
    279
  • 3.6 Testing jammed-open injectors
    280
  • 3.7 Removing and installing injectors
    282
  • 3.8 Removing and installing high-pressure lines
    286
  • 3.9 Removing and installing fuel rail
    292
  • 4 Air filter
    294
  • 4.1 Assembly overview - air filter housing
    294
  • 4.2 Removing and installing air filter housing
    296
  • 4.3 Removing and installing air guide on lock carrier
    298
  • 5 Intake manifold
    300
  • 5.1 Assembly overview – intake manifold
    300
  • 5.2 Removing and installing intake manifold
    303
  • 5.3 Removing and installing throttle valve module GX3
    307
  • 6 Senders and sensors
    310
  • 6.1 Removing and installing fuel temperature sender G81
    310
  • 6.2 Removing and installing air mass meter G70
    311
  • 6.3 Removing and installing fuel pressure regulating valve N276
    312
  • 6.4 Checking fuel pressure regulating valve N276
    314
  • 6.5 Removing and installing fuel pressure sender G247
    316
  • 6.6 Removing and installing pressure differential sender G505
    317
  • 6.7 Removing and installing exhaust gas pressure sensor 1 G450
    319
  • 6.8 Removing and installing control unit for NOx sender J583/NOx sender G295
    320
  • 6.9 Removing and installing control unit for NOx sender 2 J881/NOx sender 2 G687
    322
  • 7 Engine control unit
    325
  • 7.1 Removing and installing engine control unit J623
    325
  • 8 High-pressure pump
    329
  • 8.1 Assembly overview - high-pressure pump
    329
  • 8.2 Removing and installing high-pressure pump
    329
  • 8.3 Checking high-pressure pump
    333
  • 9 Lambda probe
    337
  • 9.1 Assembly overview - Lambda probe
    337
  • 9.2 Removing and installing Lambda probe 1 before catalytic converter GX10
    338
  • Exhaust system
    341
  • 1 Exhaust pipes and silencers
    341
  • 1.1 Assembly overview – silencers
    341
  • 1.2 Assembly overview - front exhaust pipe
    342
  • 1.3 Removing and installing front exhaust pipe
    345
  • 1.4 Separating exhaust pipes and silencers
    352
  • 1.5 Removing and installing rear silencer
    353
  • 1.6 Aligning exhaust system free of stress
    354
  • 1.7 Checking exhaust system for leaks
    355
  • 1.8 Installation position of clamp
    355
  • 2 Emission control
    357
  • 2.1 Assembly overview – emission control
    357
  • 2.2 Removing and installing catalytic converter
    365
  • 2.3 Removing and installing particulate filter
    365
  • 2.4 Removing and installing emission control module
    371
  • 2.5 Removing and installing exhaust flap control unit J883
    380
  • 3 SCR system (selective catalytic reduction)
    382
  • 3.1 Assembly overview – reducing agent tank
    382
  • 3.2 Assembly overview - delivery module for reducing agent
    383
  • 3.3 Assembly overview - injector for reducing agent
    383
  • 3.4 Draining reducing agent tank VX85
    384
  • 3.5 Removing and installing reducing agent tank VX85
    387
  • 3.6 Removing and installing front section of reducing agent supply line
    390
  • 3.7 Removing and installing delivery unit for reducing agent metering system GX19
    393
  • 3.8 Removing and installing injector for reduction agent N474
    396
  • 3.9 Removing and installing control unit for reducing-agent heater J891
    399
  • 4 Exhaust gas temperature regulation
    400
  • 4.1 Assembly overview – exhaust gas temperature regulation
    400
  • 4.2 Removing and installing exhaust gas temperature sender 1 G235
    402
  • 4.3 Removing and installing exhaust gas temperature sender 2 G448
    406
  • 4.4 Removing and installing exhaust gas temperature sender 3 G495
    407
  • 4.5 Removing and installing exhaust gas temperature sender 4 G648
    409
  • 5 Exhaust gas recirculation
    412
  • 5.1 Assembly overview – exhaust gas recirculation
    412
  • 5.2 Assembly overview - exhaust gas recirculation valve
    416
  • 5.3 Removing and installing exhaust gas recirculation cooler
    417
  • 5.4 Checking exhaust gas recirculation cooler for leaks
    426
  • 5.5 Removing and installing exhaust gas recirculation valve 1 GX5
    426
  • 5.6 Removing and installing exhaust gas recirculation valve 2 GX6
    427
  • 5.7 Removing and installing bracket for exhaust gas recirculation cooler
    429
  • 5.8 Removing and installing exhaust gas recirculation pipes
    431
  • 5.9 Removing and installing exhaust gas recirculation temperature sensor G98
    435
  • Glow plug system
    438
  • 1 Glow plug system
    438
  • 1.1 Assembly overview – glow plug system
    438
  • 1.2 Removing and installing glow plug
    439
  • 1.3 Removing and installing automatic glow period control unit J179
    442
  • 1.4 Removing and installing Hall sender G40
    443
  • 1.5 Removing and installing engine speed sender G28
    444
Manufacturer's designation 4-cylinder common rail engine (2.0 l, 4V, turbocharger)
Manufacturer Volkswagen
Suitable for Caddy (2016) / Caddy (2021 >)
Suitable car types SA, SB
Engine code DFSB, CUUD, CUUE, CUUF, DFSC, DFSD, DFSE, DFSF, CRVD
Category Reparaturanleitung

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