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  • Examplepage for repair manual 4-cylinder diesel engine (1.9 l engine)
  • Examplepage for repair manual 2 4-cylinder diesel engine (1.9 l engine)
  • Examplepage for repair manual 3 4-cylinder diesel engine (1.9 l engine)

4-cylinder diesel engine (1.9 l engine)

For Caddy

Original Volkswagen repair manual


18,15 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

8.159 KB

221 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, 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, Intake manifold, Exhaust pipes, silencers and Exhaust gas temperature regulation. Show more
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Repair manual Caddy 4-cylinder diesel engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Identification
    1
  • 1.1 Engine number, engine data
    1
  • 2 Safety instructions
    2
  • 2.1 Safety precautions when working on cooling system
    2
  • 2.2 Safety precautions when working on fuel supply system
    3
  • 2.3 Safety precautions when working on charge air system
    4
  • 2.4 Safety precautions when working on injection system
    4
  • 3 Repair instructions
    6
  • 3.1 Rules for cleanliness when working on fuel supply system/injection system
    6
  • 3.2 Rules for cleanliness when working on charge air system
    6
  • 3.3 General notes on the lubrication system
    7
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Removing engine - vehicles with four-wheel drive
    14
  • 1.3 Securing engine on engine and gearbox support VAS 6095
    21
  • 1.4 Installing engine
    22
  • 1.5 Installing engine - vehicles with four-wheel drive
    23
  • 2 Assembly mountings
    26
  • 2.1 Assembly overview - assembly mountings
    26
  • Crankshaft group
    28
  • 1 Cylinder block (pulley end)
    28
  • 1.1 Assembly overview - cylinder block
    28
  • 1.2 Assembly overview - poly V-belt drive with vane pump
    29
  • 1.3 Assembly overview - poly V-belt drive with vane pump
    30
  • 1.4 Removing and installing poly V-belt
    30
  • 1.5 Renewing crankshaft oil seal on belt pulley end
    33
  • 1.6 Removing and installing sealing flange on pulley end
    35
  • 2 Cylinder block, gearbox end
    38
  • 2.1 Assembly overview - cylinder block, gearbox end
    38
  • 2.2 Removing and installing dual-mass flywheel
    39
  • 2.3 Removing and installing sealing flange on gearbox side
    41
  • 3 Crankshaft
    50
  • 3.1 Assembly overview - crankshaft
    50
  • 3.2 Renewing needle bearing in crankshaft
    51
  • 3.3 Crankshaft dimensions
    52
  • 4 Pistons and conrods
    53
  • 4.1 Assembly overview - pistons and conrods
    53
  • 4.2 Checking piston and cylinder bore
    54
  • 4.3 Separating new conrod
    56
  • 4.4 Measuring piston projection at TDC
    56
  • 4.5 Cylinder head gasket identification
    58
  • 4.6 Piston and cylinder dimensions
    58
  • Cylinder head, valve gear
    59
  • 1 Cylinder head
    59
  • 1.1 Assembly overview - cylinder head
    59
  • 1.2 Removing and installing cylinder head
    63
  • 1.3 Removing and installing cylinder head cover
    67
  • 1.4 Checking compression
    70
  • 2 Toothed belt drive
    72
  • 2.1 Assembly overview - toothed belt drive
    72
  • 2.2 Removing and installing toothed belt
    73
  • 2.3 Loosening and securing toothed belt
    90
  • 3 Valve gear
    97
  • 3.1 Assembly overview - valve gear
    97
  • 3.2 Measuring axial play of camshaft
    99
  • 3.3 Removing and installing camshaft
    99
  • 3.4 Removing and installing camshaft oil seal
    104
  • 3.5 Removing and installing valve stem seals
    105
  • 4 Inlet and exhaust valves
    108
  • 4.1 Checking valve guides
    108
  • 4.2 Valve dimensions
    108
  • Lubrication
    109
  • 1 Sump, oil pump
    109
  • 1.1 Assembly overview - sump and oil pump
    109
  • 1.2 Removing and installing sump
    110
  • 1.3 Engine oil
    112
  • 1.4 Oil consumption measurement
    113
  • 2 Oil filter, oil pressure switch
    114
  • 2.1 Assembly overview - oil filter housing, oil pressure switch
    114
  • 2.2 Checking oil pressure and oil pressure switch
    115
  • 3 Oil circuit
    117
  • 3.1 Assembly overview - oil supply line
    117
  • 3.2 Removing and installing oil supply line
    117
  • Cooling
    120
  • 1 Cooling system, coolant
    120
  • 1.1 Coolant hose schematic diagram
    120
  • 1.2 Draining and filling coolant
    121
  • 1.3 Checking cooling system for leaks
    123
  • 1.4 Checking engine oil cooler for leaks
    125
  • 2 Coolant pump, regulation of cooling system
    128
  • 2.1 Assembly overview - coolant pump, thermostat
    128
  • 2.2 Removing and installing coolant pump
    132
  • 2.3 Removing and installing thermostat
    133
  • 3 Coolant pipes
    136
  • 3.1 Removing and installing rear coolant pipe for additional heater
    136
  • 4 Radiator, radiator fan
    139
  • 4.1 Assembly overview - radiator/radiator fan
    139
  • 4.2 Removing and installing radiator
    141
  • 4.3 Removing and installing fan support with fans
    142
  • Turbocharging/supercharging
    144
  • 1 Turbocharger
    144
  • 1.1 Assembly overview - turbocharger, engine code BJB
    144
  • 1.2 Assembly overview - turbocharger, engine codes BLS, BSU
    146
  • 1.4 Removing and installing turbocharger
    154
  • 1.5 Removing and installing turbocharger support with oil return pipe
    159
  • 2 Charge air system
    162
  • 2.1 Assembly overview - charge air system, engine code BJB
    162
  • 2.2 Assembly overview - charge air system, engine codes BLS, BSU
    164
  • 2.3 Fitting the charge-air system hose connections
    165
  • 2.4 Checking charge air system for leaks
    166
  • Mixture preparation - injection
    169
  • 1 Injectors
    169
  • 1.1 Assembly overview - unit injector
    169
  • 1.2 Removing and installing O-rings for unit injector
    170
  • 1.3 Removing and installing unit injector
    171
  • 1.4 Removing and installing prewiring for unit injectors
    174
  • 2 Vacuum system
    178
  • 2.1 Connection overview
    178
  • 2.2 Schematic diagram - vacuum system, engine code BJB
    178
  • 2.3 Schematic diagram - vacuum system, engine codes BLS, BSU
    180
  • 3 Air filter
    181
  • 3.1 Assembly overview - air filter
    181
  • 4 Intake manifold
    182
  • 4.1 Assembly overview - intake manifold, engine code BJB
    182
  • 4.2 Assembly overview - intake manifold, engine codes BLS, BSU
    182
  • 4.3 Cleaning intake manifold flap connection, engine codes BLS, BSU
    183
  • 5 Engine control unit
    185
  • 5.1 Removing and installing engine control unit
    185
  • 6 High-pressure pump
    187
  • 6.1 Removing and installing fuel pump
    187
  • Exhaust system
    193
  • 1 Exhaust pipes, silencers
    193
  • 1.1 Separating exhaust pipes, silencers
    193
  • 1.2 Aligning exhaust system free of stress
    193
  • 2 Emission control
    195
  • 2.1 Assembly overview – emission control with catalytic converter
    195
  • 2.3 Removing and installing particulate filter
    199
  • 2.4 Removing and installing particulate filter - vehicles with four-wheel drive
    202
  • 3 Exhaust gas temperature regulation
    206
  • 3.1 Assembly overview - exhaust gas temperature regulation
    206
  • 4 Exhaust gas recirculation system
    207
  • 4.1 Assembly overview - exhaust gas recirculation system, engine code BJB
    207
  • 4.2 Assembly overview - exhaust gas recirculation system, engine codes BLS, BSU
    208
  • 4.3 Removing and installing exhaust gas recirculation cooler, engine codes BLS, BSU
    209
  • 4.4 Checking mechanical exhaust gas recirculation valve, engine code BJB
    211
  • Glow plug system
    212
  • 1 Glow plug system
    212
  • 1.1 Removing, installing and checking glow plugs
    212
  • 1.2 Removing, installing and checking ceramic glow pin plugs
    213
  • 1.3 Removing and installing engine speed sender G28
    215
Manufacturer's designation 4-cylinder diesel engine (1.9 l engine)
Manufacturer Volkswagen
Suitable for Caddy (2004 - 2010)
Suitable car types 2K
Engine code BJB, BLS
Category Reparaturanleitung

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