THE CAR REPAIR SHOP
0
Home » Manuals » 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.6 l engine, common rail)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.6 l engine, common rail)

4-cylinder diesel engine (1.6 l engine, common rail)

For Caddy KA / Caddy Maxi

Original Volkswagen repair manual


29,15 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

21.325 KB

384 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, Fully enclosing toothed belt guard, 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 Exhaust gas temperature regulation. Show more
Secure Payment via PayPal, credit card, direct debit and more
PayPal Logo SEPA Lastschrift Logo Giropay Logo Sofort Überweisung Logo

Repair manual Caddy KA / Caddy Maxi 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety precautions when working on the cooling system
    1
  • 1.2 Safety measures when working on fuel supply
    2
  • 1.4 Safety precautions when working on injection system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 General information
    5
  • 3.1 General notes on injection
    5
  • 3.2 General notes on the lubrication system
    5
  • 3.3 General notes on fuel system
    6
  • 4 Repair instructions
    8
  • 4.1 Rules for cleanliness when working on fuel supply system
    8
  • 4.2 Rules for cleanliness when working on injection system
    8
  • 4.3 Rules for cleanliness when working on turbocharger
    9
  • 4.4 Foreign objects in engine
    9
  • Removing and installing engine
    10
  • 1 Removing and installing engine
    10
  • 1.1 Removing engine
    10
  • 1.2 Separating engine from gearbox
    22
  • 1.3 Separating engine from dual clutch gearbox
    23
  • 1.4 Securing engine on engine and gearbox support
    25
  • 1.5 Installing engine
    26
  • 2 Assembly mountings
    32
  • 2.1 Assembly overview - assembly mountings
    32
  • 2.2 Removing and installing engine mounting
    35
  • 2.3 Removing and installing engine bracket
    37
  • 2.4 Supporting engine in installation position
    40
  • 2.5 Adjusting assembly mountings
    43
  • 3 Engine cover panel
    47
  • 3.1 Removing and installing engine cover
    47
  • Crankshaft group
    48
  • 1 Cylinder block (pulley end)
    48
  • 1.1 Assembly overview - cylinder block
    48
  • 1.2 Assembly overview - sealing flange, belt pulley end
    50
  • 1.3 Assembly overview - poly V-belt drive without air conditioner compressor
    51
  • 1.4 Assembly overview - poly V-belt drive with air conditioning compressor
    52
  • 1.5 Assembly overview - ancillary bracket
    53
  • 1.6 Removing and installing sealing flange on pulley end
    53
  • 1.7 Renewing crankshaft oil seal - belt pulley end
    56
  • 1.8 Removing and installing bracket for ancillaries
    58
  • 1.9 Removing and installing poly V-belt without air conditioner compressor
    61
  • 1.10 Removing and installing poly V-belt with air conditioner compressor
    61
  • 1.11 Removing and installing tensioner for poly V-belt
    63
  • 1.12 Removing and installing vibration damper
    64
  • 2 Cylinder block, gearbox end
    66
  • 2.1 Assembly overview - flywheel
    66
  • 2.2 Removing and installing flywheel
    67
  • 2.3 Removing and installing sealing flange on gearbox side
    68
  • 3 Crankshaft
    76
  • 3.1 Assembly overview - crankshaft
    76
  • 3.2 Crankshaft dimensions
    77
  • 3.3 Renewing needle bearing in crankshaft
    77
  • 4 Pistons and conrods
    79
  • 4.1 Assembly overview - pistons and conrods
    79
  • 4.2 Checking pistons and cylinder bores
    81
  • 4.3 Piston and cylinder dimensions
    82
  • 4.4 Separating new conrod
    82
  • 4.5 Measuring piston projection at TDC
    83
  • 4.6 Checking radial clearance of conrods
    84
  • 4.7 Removing and installing oil spray jets
    85
  • Cylinder head, valve gear
    87
  • 1 Cylinder head
    87
  • 1.1 Assembly overview - cylinder head
    87
  • 1.2 Assembly overview - cylinder head cover
    89
  • 1.3 Removing and installing cylinder head
    91
  • 1.4 Removing and installing cylinder head cover
    106
  • 1.5 Removing and installing injector seals
    111
  • 1.6 Removing and installing vacuum pump
    114
  • 1.7 Checking compression
    115
  • 2 Fully enclosing toothed belt guard
    117
  • 2.1 Assembly overview - fully enclosing toothed belt guard
    117
  • 2.2 Removing and installing upper toothed belt guard (fully enclosing)
    118
  • 2.3 Removing and installing lower toothed belt guard (fully enclosed)
    119
  • 2.4 Removing and installing rear toothed belt guard (fully enclosing)
    120
  • 3 Toothed belt drive
    125
  • 3.1 Assembly overview - toothed belt drive
    125
  • 3.2 Removing and installing toothed belt
    127
  • 4 Valve gear
    141
  • 4.1 Assembly overview - valve gear
    141
  • 4.2 Removing and installing camshafts
    144
  • 4.3 Measuring axial play of camshaft
    151
  • 4.4 Measuring radial play of camshaft
    152
  • 4.5 Removing and installing camshaft oil seal
    152
  • 4.6 Checking hydraulic compensation elements
    155
  • 4.7 Removing and installing valve stem seals
    155
  • 4.8 Removing and installing valve stem seals with cylinder head removed
    159
  • 5 Inlet and exhaust valves
    163
  • 5.1 Reworking valve seats
    163
  • 5.2 Checking valve guides
    163
  • 5.3 Checking valves
    164
  • 5.4 Valve dimensions
    164
  • Lubrication
    165
  • 1 Sump, oil pump
    165
  • 1.1 Assembly overview - sump/oil pump
    165
  • 1.2 Removing and installing sump
    167
  • 1.3 Removing and installing oil pump
    171
  • 1.4 Engine oil:
    173
  • 1.5 Removing and installing oil level and oil temperature sender G266
    173
  • 1.6 Measuring oil consumption
    174
  • 2 Engine oil cooler
    175
  • 2.1 Removing and installing engine oil cooler
    175
  • 3 Oil filter, oil pressure switch
    179
  • 3.1 Assembly overview - oil filter housing with engine oil cooler
    179
  • 3.2 Removing and installing oil filter housing
    180
  • 3.3 Removing and installing oil pressure switch F1
    183
  • 3.4 Checking oil pressure switch
    185
  • 3.5 Checking oil pressure
    186
  • 4 Oil circuit
    188
  • 4.1 Assembly overview - oil circuit
    188
  • 4.2 Removing and installing oil supply line
    189
  • Cooling
    193
  • 1 Cooling system/coolant
    193
  • 1.1 Connection diagram - coolant hoses
    193
  • 1.2 Draining and adding coolant
    194
  • 1.3 Checking cooling system for leaks
    202
  • 1.4 Checking engine oil cooler for leaks
    204
  • 2 Coolant pump, regulation of cooling system
    206
  • 2.1 Assembly overview - coolant pump, thermostat
    206
  • 2.2 Assembly overview - coolant pump and thermostat, from week 22/2011
    207
  • 2.3 Removing and installing coolant pump
    207
  • 2.4 Removing and installing 4/2-way valve with thermostat
    208
  • 2.5 Removing and installing coolant temperature sender G62
    214
  • 2.6 Removing and installing radiator outlet coolant temperature sender G83
    215
  • 2.7 Removing and installing coolant circulation pump 2 V178
    216
  • 3 Radiator, radiator fan
    219
  • 3.1 Assembly overview - radiator/radiator fan
    219
  • 3.3 Removing and installing radiator
    221
  • 4 Coolant pipes
    224
  • 4.1 Assembly overview - coolant pipes
    224
  • 4.2 Removing and installing lower coolant pipe
    225
  • 4.3 Removing and installing upper coolant pipe
    229
  • 4.4 Removing and installing left coolant pipe
    230
  • 4.5 Removing and installing right coolant pipe
    232
  • Turbocharging/supercharging
    235
  • 1 Turbocharger
    235
  • 1.1 Assembly overview - turbocharger
    235
  • 1.2 Removing and installing turbocharger
    239
  • 1.3 Removing and installing charge pressure control solenoid valve N75
    244
  • 2 Charge air system
    247
  • 2.1 Assembly overview - charge air system
    247
  • 2.2 Assembly overview - charge-air hose connections
    248
  • 2.3 Removing and installing charge air cooler
    249
  • 2.4 Removing and installing charge air pipe
    251
  • 2.5 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
    252
  • 2.6 Checking charge air system for leaks
    252
  • Mixture preparation - injection
    256
  • 1 Injection system
    256
  • 1.1 Schematic overview - fuel system
    256
  • 1.2 Overview of fitting locations - injection system
    258
  • 1.3 Assembly overview - fuel system
    267
  • 1.4 Checking fuel system for leaks
    270
  • 1.5 Filling/bleeding fuel system
    270
  • 2 Vacuum system
    272
  • 2.1 Connection diagram - vacuum system
    272
  • 2.2 Checking vacuum system
    273
  • 3 Injectors/high-pressure accumulator (rail)
    281
  • 3.1 Overview - fuel return lines
    281
  • 3.2 Assembly overview - injectors
    282
  • 3.3 Removing and installing high-pressure lines
    282
  • 3.4 Removing and installing fuel rail
    288
  • 3.5 Removing and installing injectors
    292
  • 3.6 Adapting correction values for injectors
    297
  • 3.7 Replacing O-ring of fuel return lines
    298
  • 3.8 Check pressure retention valve in fuel return line
    298
  • 3.9 Checking return flow rate of injectors at starter speed
    300
  • 3.10 Testing injectors
    301
  • 4 High-pressure pump
    303
  • 4.1 Assembly overview - high-pressure pump
    303
  • 4.2 Removing and installing high-pressure pump
    304
  • 4.3 Pressure testing high-pressure pump
    308
  • 4.4 Checking high-pressure pump
    310
  • 5 Intake manifold
    313
  • 5.1 Assembly overview - intake manifold
    313
  • 5.2 Removing and installing intake manifold
    314
  • 5.3 Removing and installing throttle valve module GX3
    318
  • 6 Air filter
    320
  • 6.1 Assembly overview - air filter housing
    320
  • 6.2 Removing and installing air filter housing
    321
  • 7 Lambda probe
    323
  • 7.1 Removing and installing Lambda probe G39
    323
  • 8 Senders and sensors
    325
  • 8.1 Removing and installing air mass meter G70
    325
  • 8.2 Removing and installing pressure differential sender G505
    326
  • 8.3 Removing and installing fuel pressure regulating valve N276
    326
  • 8.4 Checking fuel pressure regulating valve N276
    329
  • 8.5 Removing and installing fuel pressure sender G247
    331
  • 8.6 Checking fuel pressure sender G 247
    334
  • 8.7 Checking fuel metering valve N 290
    335
  • 9 Engine control unit
    336
  • 9.1 Removing and installing engine control unit J623
    336
  • 9.2 Removing and installing anti-theft engine control unit J623
    337
  • Exhaust system
    340
  • 1 Exhaust pipes and silencers
    340
  • 1.1 Assembly overview - silencers
    340
  • 1.2 Separating exhaust pipes from silencers
    341
  • 1.3 Aligning exhaust system free of stress
    342
  • 1.4 Installation position of clamp
    343
  • 2 Emission control
    344
  • 2.1 Assembly overview - catalytic converter
    344
  • 2.2 Assembly overview - particulate filter
    346
  • 2.3 Removing and installing particulate filter
    347
  • 3 Exhaust gas temperature regulation
    352
  • 3.1 Assembly overview - exhaust gas temperature regulation
    352
  • 3.2 Removing and installing exhaust gas temperature sender 1 G235
    353
  • 3.3 Removing and installing exhaust gas temperature sender 3 G495
    354
  • 3.4 Removing and installing exhaust gas temperature sender 4 G648
    356
  • 4 Exhaust gas recirculation
    359
  • 4.1 Assembly overview - exhaust gas recirculation
    359
  • 4.2 Checking changeover for exhaust gas recirculation cooler
    360
  • 4.3 Removing and installing exhaust gas recirculation cooler
    361
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    363
  • 4.5 Cleaning exhaust gas recirculation system
    364
  • Glow plug system
    371
  • 1 Glow plug system
    371
  • 1.1 Removing and installing glow plug
    371
  • 1.2 Checking glow plugs
    373
  • 1.3 Removing and installing automatic glow period control unit J179
    373
  • 1.4 Removing and installing engine speed sender G28
    374
  • 1.5 Removing and installing Hall sender G40
    375
Manufacturer's designation 4-cylinder diesel engine (1.6 l engine, common rail)
Manufacturer Volkswagen
Suitable for Caddy KA / Caddy Maxi (2011)
Suitable car types 2C
Engine code CAYE
Category Reparaturanleitung

There are no reviews for this product at the moment.

Similar repair manuals

4-cylinder injection engine (1.6 l roller rocker finger)

Examplepage for repair manual 4-cylinder injection engine (1.6 l roller rocker finger)

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

14,00 € Details

6-speed dual clutch gearbox 02E

Examplepage for repair manual 6-speed dual clutch gearbox 02E

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

15,97 € Details

7-speed dual clutch gearbox 0AM

Examplepage for repair manual 7-speed dual clutch gearbox 0AM

For Caddy KA / Caddy Maxi (2011)

15,09 € Details

General body repairs, exterior

Examplepage for repair manual General body repairs, exterior

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

31,26 € Details

Running gear, axles, steering

Examplepage for repair manual Running gear, axles, steering

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

27,20 € Details

5-speed manual gearbox 0AH

Examplepage for repair manual 5-speed manual gearbox 0AH

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

15,24 € Details

General body repairs, interior

Examplepage for repair manual General body repairs, interior

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

26,82 € Details

Body Repairs

Examplepage for repair manual Body Repairs

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

23,15 € Details

Propshaft and rear final drive

Examplepage for repair manual Propshaft and rear final drive

For Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)

6,06 € Details

Guide for using trailers

Examplepage for repair manual Guide for using trailers

For Caddy Pickup (1997 - 2002) / Caddy Kasten/Kombi (1996 - 2003) / Transporter Kasten (1996 - 2003) / CRAFTER (2006 - 2007) / Transporter (2003 - 2007) / LT 2006> (2006 - 2007) / LT 28-35 Kasten 2500 (1996 - 2006) / Transporter Kasten (1991 - 1996) / Transporter (2003 - 2007) / Amarok (2011) / Caddy (2004 - 2010) / Caddy KA (2011) / Transporter T5 (2010) / Transporter T5 (2010) / Amarok (2013) / Caddy (2016) / Transporter (2016) / Transporter (2016) / Amarok (2017 >) / Amarok (2017) / Crafter () / Crafter () / TGE (2017 > ) / TGE (2017 > ) / Transporter (2020 >) / Transporter (2020 >) / Crafter () / Crafter () / Caddy (2021 >)

28,22 € Details

Our Best Sellers

Did you know? We also offer original spare parts.

car part 1J0971921K Kappe

1J0971921K

Kappe

1,29 €

Details
car part 2Q0971349LH Leitg.Satz

2Q0971349LH

Leitg.Satz

222,38 €

Details
car part 047103147 Dichtung

047103147

Dichtung

0,62 €

Details
car part 0CF311315B Buchse

0CF311315B

Buchse

29,76 €

Details
car part 02M409356A Flanwelle

02M409356A

Flanwelle

115,64 €

Details

4-Zylinder-Dieselmotor (1,9 l-Motor) 028.B / ADE / ADG

Examplepage for repair manual 4-Zylinder-Dieselmotor (1,9 l-Motor) 028.B / ADE / ADG

For Industriemotoren - Industrial Engines ()

7,57 € Details

Nr. 528: Der Erdgasantrieb im Golf/Golf Variant TGI BlueMotion

Examplepage for repair manual Nr. 528: Der Erdgasantrieb im Golf/Golf Variant TGI BlueMotion

5,26 € Details

Kardanwelle und Achsantrieb hinten

Examplepage for repair manual Kardanwelle und Achsantrieb hinten

For Passat / Passat Variant (2005 - 2008) / Golf (2004 - 2007) / Tiguan (2008) / Passat CC (2009) / Golf (2009) / Sharan (2011)

20,15 € Details

image/svg+xml About Clonck

Original repair manuals und spare parts

Our repair manuals are original, come directly from Volkswagen and meet the highest quality standards.

In our original parts shop we sell high-quality original spare parts from car manufacturers. Use the search function to enter the desired part number (OE number) and order the required spare part quickly and easily.

Highest quality standards

At Clonck, we want to make car mechanics and car professionals happy. That's why you will only find professional and high-quality repair manuals at Clonck that will help you to repair your vehicle professionally.

Our partners

Autohaus Schmidt GmbH
Automag GmbH Filiale Laim
KFZ-VERLAG GmbH
Zimpel und Franke GmbH

Clonck: The car repair shop - also as app!

Clonck App Logo Play Store

Clonck: Fitting car parts for your car repair

4,5 90

With Clonck you can order the right original spare parts in no time.

  • Add your car model
  • Select assembly group
  • Enter vehicle identification number (VIN)
  • Access to over 5,000 original repair manuals
Start app now
Clonck App Preview Car Mobilephone Carparts