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

Original Volkswagen repair manual


31,50 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

28.478 KB

423 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 4-cylinder diesel 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 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
    6
  • 3.1 Rules for cleanliness
    6
  • 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 Fitting radiator and condensers
    8
  • 3.7 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
    22
  • 1.3 Securing engine on engine and gearbox support
    26
  • 1.4 Installing engine
    28
  • 2 Assembly mountings
    33
  • 2.1 Assembly overview - assembly mountings
    33
  • 2.2 Removing and installing engine mounting
    35
  • 2.3 Removing and installing gearbox mounting
    38
  • 2.4 Removing and installing pendulum support
    39
  • 2.5 Supporting engine in installation position
    42
  • 2.6 Adjusting assembly mountings
    44
  • 2.7 Checking adjustment of assembly mountings
    48
  • 3 Engine cover panel
    50
  • 3.1 Removing and installing engine cover
    50
  • Crankshaft group
    51
  • 1 Cylinder block (pulley end)
    51
  • 1.1 Assembly overview - poly V-belt drive
    51
  • 1.2 Assembly overview - cylinder block (pulley end)
    53
  • 1.3 Assembly overview - sealing flange, belt pulley end
    56
  • 1.4 Removing and installing poly-V belt
    57
  • 1.5 Removing and installing tensioner for poly V-belt
    59
  • 1.6 Removing and installing vibration damper
    60
  • 1.7 Removing and installing bracket for ancillaries
    61
  • 1.8 Removing and installing engine support
    64
  • 1.9 Renewing crankshaft oil seal - belt pulley end
    66
  • 1.10 Removing and installing sealing flange on pulley end
    68
  • 2 Cylinder block, gearbox end
    73
  • 2.1 Assembly overview - cylinder block, gearbox end
    73
  • 2.2 Removing and installing flywheel
    74
  • 2.3 Removing and installing sealing flange on gearbox side
    75
  • 3 Crankshaft
    86
  • 3.1 Assembly overview - crankshaft
    86
  • 3.2 Crankshaft dimensions
    87
  • 3.3 Renewing needle bearing in crankshaft
    88
  • 3.4 Measuring axial clearance of crankshaft
    90
  • 4 Pistons and conrods
    92
  • 4.1 Assembly overview - pistons and conrods
    92
  • 4.2 Removing and installing pistons
    95
  • 4.3 Measuring piston projection at TDC
    96
  • 4.4 Checking pistons and cylinder bores
    98
  • 4.5 Separating new conrod
    100
  • 4.6 Checking radial clearance of conrods
    101
  • 4.7 Removing and installing oil spray jets
    101
  • Cylinder head, valve gear
    103
  • 1 Cylinder head
    103
  • 1.1 Assembly overview - cylinder head
    103
  • 1.2 Assembly overview - cylinder head cover
    107
  • 1.3 Removing and installing cylinder head
    109
  • 1.4 Removing and installing cylinder head cover
    125
  • 1.5 Removing and installing injector seals
    132
  • 1.6 Removing and installing vacuum pump
    133
  • 1.7 Checking compression
    135
  • 2 Fully enclosing toothed belt guard
    137
  • 2.1 Assembly overview - fully enclosing toothed belt guard
    137
  • 2.2 Removing and installing upper toothed belt guard (fully enclosing)
    139
  • 2.3 Removing and installing lower toothed belt guard (fully enclosed)
    140
  • 2.4 Removing and installing rear toothed belt guard (fully enclosing)
    141
  • 3 Toothed belt drive
    146
  • 3.1 Assembly overview - toothed belt
    146
  • 3.2 Removing and installing toothed belt
    149
  • 4 Valve gear
    165
  • 4.1 Assembly overview - valve gear
    165
  • 4.2 Measuring axial play of camshaft
    168
  • 4.3 Measuring radial play of camshaft
    169
  • 4.4 Removing and installing camshaft oil seal
    169
  • 4.5 Removing and installing camshaft
    172
  • 4.6 Checking hydraulic compensation elements
    181
  • 4.7 Removing and installing valve stem seals
    182
  • 5 Inlet and exhaust valves
    192
  • 5.1 Reworking valve seats
    192
  • 5.2 Checking valve guides
    192
  • 5.3 Checking valves
    193
  • 5.4 Valve dimensions
    193
  • Lubrication
    194
  • 1 Sump, oil pump
    194
  • 1.1 Assembly overview - sump/oil pump
    194
  • 1.2 Engine oil:
    197
  • 1.3 Removing and installing oil sump
    198
  • 1.4 Removing and installing oil pump
    202
  • 1.5 Removing and installing oil level and oil temperature sender G266
    204
  • 2 Engine oil cooler
    206
  • 2.1 Assembly overview - engine oil cooler
    206
  • 2.2 Removing and installing engine oil cooler
    206
  • 3 Oil filter, oil pressure switch
    211
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    211
  • 3.2 Removing and installing oil filter housing
    212
  • 3.3 Removing and installing oil pressure switch F1
    215
  • 3.4 Checking oil pressure and oil pressure switch
    217
  • 4 Oil circuit
    219
  • 4.1 Assembly overview - oil circuit
    219
  • 4.2 Removing and installing oil return line for turbocharger
    220
  • Cooling
    226
  • 1 Cooling system/coolant
    226
  • 1.1 Connection diagram - coolant hoses
    226
  • 1.2 Checking cooling system for leaks
    228
  • 1.3 Draining and adding coolant
    233
  • 2 Coolant pump, regulation of cooling system
    243
  • 2.1 Assembly overview - coolant pump, thermostat
    243
  • 2.2 Removing and installing coolant circulation pump 2 V178
    243
  • 2.3 Removing and installing coolant pump
    246
  • 2.4 Removing and installing 4/2-way valve with thermostat
    247
  • 2.5 Removing and installing coolant temperature sender G62
    249
  • 2.6 Removing and installing radiator outlet coolant temperature sender G83
    251
  • 3 Coolant pipes
    254
  • 3.1 Assembly overview - coolant pipes
    254
  • 3.2 Removing and installing coolant pipes
    256
  • 4 Radiator, radiator fan
    264
  • 4.1 Assembly overview - radiator, radiator fan
    264
  • 4.2 Assembly overview – radiator cowl and radiator fan
    265
  • 4.3 Removing and installing radiator
    266
  • 4.4 Removing and installing radiator cowl with radiator fan
    267
  • 4.5 Removing and installing radiator fan VX57
    268
  • 4.6 Removing and installing radiator fan 2 V177
    269
  • Turbocharging/supercharging
    271
  • 1 Turbocharger
    271
  • 1.1 Assembly overview - turbocharger
    271
  • 1.2 Removing and installing turbocharger
    274
  • 2 Charge air system
    279
  • 2.1 Assembly overview - charge air system
    279
  • 2.2 Assembly overview - charge-air hose connections
    281
  • 2.3 Removing and installing charge air cooler
    282
  • 2.5 Checking charge air system for leaks
    285
  • 2.6 Removing and installing air pipe
    289
  • Mixture preparation - injection
    292
  • 1 Injection system
    292
  • 1.1 Schematic overview - fuel system
    292
  • 1.2 Overview of fitting locations - injection system
    294
  • 1.3 Assembly overview - fuel system
    297
  • 1.4 Filling/bleeding fuel system
    300
  • 1.5 Checking fuel system for leaks
    301
  • 2 Vacuum system
    302
  • 2.1 Connection diagram – vacuum system
    302
  • 2.2 Checking vacuum system
    303
  • 3 Injectors/high-pressure accumulator (rail)
    315
  • 3.1 Assembly overview - injectors
    315
  • 3.2 Assembly overview - fuel rail
    316
  • 3.3 Adapting correction values for injectors
    316
  • 3.4 Testing injectors
    317
  • 3.5 Checking return flow rate of injectors with engine running
    318
  • 3.6 Checking return flow rate of injectors at starter speed
    321
  • 3.7 Testing jammed-open injectors
    323
  • 3.8 Check pressure retention valve in fuel return line
    324
  • 3.9 Removing and installing injectors
    326
  • 3.10 Removing and installing high-pressure lines
    332
  • 3.11 Removing and installing fuel rail
    336
  • 4 Air filter
    340
  • 4.1 Assembly overview - air filter housing
    340
  • 4.2 Removing and installing air filter housing
    342
  • 5 Intake manifold
    345
  • 5.1 Assembly overview – intake manifold
    345
  • 5.2 Removing and installing intake manifold
    347
  • 5.3 Removing and installing throttle valve module GX3
    351
  • 6 Senders and sensors
    352
  • 6.1 Removing and installing fuel pressure regulating valve N276
    352
  • 6.2 Checking fuel pressure regulating valve N276
    354
  • 6.3 Removing and installing fuel pressure sender G247
    356
  • 6.4 Removing and installing air mass meter G70
    358
  • 6.5 Removing and installing pressure differential sender G505
    359
  • 7 Engine control unit
    360
  • 7.1 Removing and installing engine (motor) control unit J623 with protective housing
    360
  • 8 High-pressure pump
    363
  • 8.1 Assembly overview - high-pressure pump
    363
  • 8.2 Removing and installing high-pressure pump
    363
  • 8.3 Checking high-pressure pump
    367
  • 9 Lambda probe
    370
  • 9.1 Removing and installing Lambda probe
    370
  • Exhaust system
    372
  • 1 Exhaust pipes and silencers
    372
  • 1.1 Assembly overview – silencers
    372
  • 1.2 Separating exhaust pipes from silencers
    373
  • 1.3 Aligning exhaust system free of stress
    374
  • 1.4 Checking exhaust system for leaks
    376
  • 1.5 Installation position of clamp
    376
  • 2 Emission control
    379
  • 2.1 Assembly overview – emission control
    379
  • 2.2 Removing and installing particulate filter
    381
  • 3 Exhaust gas temperature regulation
    388
  • 3.1 Assembly overview – exhaust gas temperature regulation
    388
  • 3.2 Removing and installing exhaust gas temperature sender 1 G235
    389
  • 3.3 Removing and installing exhaust gas temperature sender 3 G495
    391
  • 3.4 Removing and installing exhaust gas temperature sender 4 G648
    393
  • 4 Exhaust gas recirculation
    395
  • 4.1 Assembly overview – exhaust gas recirculation
    395
  • 4.2 Removing and installing exhaust gas recirculation cooler
    397
  • 4.3 Checking exhaust gas recirculation cooler for leaks
    399
  • 4.4 Checking changeover for exhaust gas recirculation cooler
    399
  • 4.5 Cleaning exhaust gas recirculation system
    400
  • Glow plug system
    410
  • 1 Glow plug system
    410
  • 1.1 Removing and installing glow plug
    410
  • 1.2 Checking glow plug
    412
  • 1.3 Removing and installing automatic glow period control unit J179
    412
  • 1.4 Removing and installing Hall sender G40
    413
  • 1.5 Removing and installing engine speed sender G28
    414
Manufacturer's designation 4-cylinder diesel engine (1.6 l engine, common rail)
Manufacturer Volkswagen
Suitable for Caddy (2016)
Suitable car types SA
Engine code CAYE
Category Reparaturanleitung

There are no reviews for this product at the moment.

Similar repair manuals

Running gear, axles, steering

Examplepage for repair manual Running gear, axles, steering

For Caddy (2016)

25,77 € Details

Fuel supply system, petrol engines

Examplepage for repair manual Fuel supply system, petrol engines

For Caddy (2016)

6,64 € Details

6-speed manual gearboxes 02Q and 0BB

Examplepage for repair manual 6-speed manual gearboxes 02Q and 0BB

For Caddy (2016)

28,90 € Details

7-speed dual clutch gearbox 0AM

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

For Caddy (2016)

13,63 € Details

Brake system

Examplepage for repair manual Brake system

For Caddy (2016)

12,76 € Details

Communication

Examplepage for repair manual Communication

For Caddy (2016)

9,91 € Details

Supplementary heater

Examplepage for repair manual Supplementary heater

For Caddy (2016)

6,12 € Details

6-speed dual clutch gearbox 02E

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

For Caddy (2016)

19,30 € Details

General body repairs, interior

Examplepage for repair manual General body repairs, interior

For Caddy (2016)

30,13 € Details

4-cylinder diesel engine (2.0 l engine, common rail, generation II)

Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine, common rail, generation II)

For Caddy (2016)

34,16 € Details

Our Best Sellers

Did you know? We also offer original spare parts.

car part 000979131 Einzelltg.

000979131

Einzelltg.

3,76 €

Details
car part 4K8853294ET94 Abdeckung

4K8853294ET94

Abdeckung

27,64 €

Details
car part 3G9877439 Dichtung

3G9877439

Dichtung

102,91 €

Details
car part 7M3253243 Waermblech

7M3253243

Waermblech

92,92 €

Details
car part n10255601 Klemmschel

n10255601

Klemmschel

1,71 €

Details

Heizung, Klimaanlage

Examplepage for repair manual Heizung, Klimaanlage

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

12,76 € Details

Ratgeber Räder, Reifen

Examplepage for repair manual Ratgeber Räder, Reifen

For Touran (2016 > )

5,52 € Details

Heizung, Klimaanlage

Examplepage for repair manual Heizung, Klimaanlage

For Beetle (NBL) Limousine (2012) / Beetle (NBC) Cabrio (2012)

15,89 € 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