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  • Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 2 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 3 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 2 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
  • Examplepage for repair manual 3 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)

4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)

For Caddy

Original Volkswagen repair manual


14,43 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.094 KB

170 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 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 information
    2
  • 2.1 Safety precautions when working on injection system
    2
  • 2.2 Safety precautions when working on charge air system
    3
  • 2.3 Safety measures when working on fuel supply
    3
  • 2.4 Safety precautions when working on the cooling system
    4
  • 3 Repair instructions
    5
  • 3.1 Rules for cleanliness during work on fuel system
    5
  • 3.2 Rules for cleanliness when working on fuel supply system/injection system
    5
  • 3.3 General notes on the lubrication system
    5
  • Removing and installing engine
    7
  • 1 Removing and installing engine
    7
  • 1.1 Removing engine
    7
  • 1.2 Securing engine on engine and gearbox support
    12
  • 1.3 Installing engine
    14
  • 2 Assembly mountings
    16
  • 2.1 Assembly overview - assembly mountings
    16
  • Crankshaft group
    18
  • 1 Cylinder block (pulley end)
    18
  • 1.1 Assembly overview - poly V-belt drive
    18
  • 1.2 Assembly overview - cylinder block
    19
  • 1.3 Removing and installing poly-V belt
    20
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    22
  • 1.5 Removing and installing sealing flange on pulley end
    24
  • 2 Cylinder block, gearbox end
    28
  • 2.1 Assembly overview - cylinder block, gearbox end
    28
  • 2.2 Removing and installing sealing flange on gearbox side
    29
  • 3 Crankshaft
    38
  • 3.1 Assembly overview - crankshaft
    38
  • 3.2 Crankshaft dimensions
    38
  • 3.3 Renewing needle bearing in crankshaft
    39
  • 4 Pistons and conrods
    41
  • 4.1 Assembly overview - pistons and conrods
    41
  • 4.2 Measuring piston projection at TDC
    42
  • 4.3 Piston and cylinder dimensions
    43
  • 4.4 Checking pistons and cylinder bores
    43
  • Cylinder head, valve gear
    46
  • 1 Cylinder head
    46
  • 1.1 Assembly overview - cylinder head
    46
  • 1.2 Removing and installing cylinder head
    49
  • 1.3 Removing and installing cylinder head cover
    56
  • 1.4 Checking compression
    58
  • 2 Toothed belt drive
    60
  • 2.1 Assembly overview - toothed belt drive
    60
  • 2.2 Removing and installing toothed belt
    62
  • 2.3 Loosening and securing toothed belt
    69
  • 3 Valve gear
    75
  • 3.1 Assembly overview - valve gear
    75
  • 3.2 Measuring axial play of camshaft
    77
  • 3.3 Removing and installing camshaft oil seal
    77
  • 3.4 Removing and installing camshaft
    79
  • 3.5 Removing and installing valve stem seals
    83
  • 4 Inlet and exhaust valves
    86
  • 4.1 Checking valve guides
    86
  • 4.2 Valve dimensions
    86
  • Lubrication
    87
  • 1 Sump, oil pump
    87
  • 1.1 Assembly overview - sump/oil pump
    87
  • 1.2 Removing and installing sump
    89
  • 1.3 Engine oil:
    91
  • 2 Oil filter, oil pressure switch
    92
  • 2.1 Assembly overview - oil filter housing with engine oil cooler
    92
  • 2.2 Checking oil pressure and oil pressure switch
    93
  • 2.3 Measuring oil consumption
    94
  • Cooling
    95
  • 1 Cooling system/coolant
    95
  • 1.1 Connection diagram - coolant hoses
    95
  • 1.2 Draining and adding coolant
    96
  • 1.3 Checking cooling system for leaks
    103
  • 1.4 Checking engine oil cooler for leaks
    104
  • 2 Coolant pump, regulation of cooling system
    107
  • 2.1 Assembly overview - coolant pump, thermostat
    107
  • 2.2 Removing and installing coolant pump
    109
  • 2.3 Removing and installing thermostat
    110
  • 3 Radiator, radiator fan
    113
  • 3.1 Assembly overview - radiator/radiator fan
    113
  • 3.2 Removing and installing radiator
    115
  • 3.3 Removing and installing fan mounting with fans
    116
  • Turbocharging/supercharging
    119
  • 1 Turbocharger
    119
  • 1.1 Assembly overview - turbocharger
    119
  • 1.2 Removing and installing turbocharger
    121
  • 2 Charge air system
    125
  • 2.1 Assembly overview - charge air system
    125
  • 2.2 Assembly overview - charge-air hose connections
    126
  • 2.3 Checking charge air system for leaks
    126
  • Mixture preparation - injection
    129
  • 1 Injectors
    129
  • 1.1 Assembly overview - injectors
    129
  • 1.2 Assembly overview - prewiring for unit injectors
    130
  • 1.3 Removing and installing O-rings for unit injector
    130
  • 1.4 Removing and installing unit injector
    131
  • 1.5 Removing and installing prewiring for unit injectors
    134
  • 2 Vacuum system
    138
  • 2.1 Connection diagram - vacuum system
    138
  • 3 Air filter
    139
  • 3.1 Assembly overview - air filter housing
    139
  • 4 Intake manifold
    140
  • 4.1 Assembly overview - intake manifold
    140
  • 4.2 Cleaning intake manifold flap connection
    141
  • 5 Engine control unit
    142
  • 5.1 Removing and installing engine control unit
    142
  • 6 High-pressure pump
    144
  • 6.1 Removing and installing tandem pump
    144
  • 6.2 Checking delivery pressure of tandem pump
    146
  • 6.3 Checking for internal leaks
    148
  • Exhaust system
    150
  • 1 Exhaust pipes and silencers
    150
  • 1.1 Assembly overview - silencers
    150
  • 1.2 Separating exhaust pipes from silencers
    151
  • 1.3 Installation position of clamp
    152
  • 1.4 Aligning exhaust system free of stress
    152
  • 2 Emission control
    153
  • 2.1 Assembly overview - emission control
    153
  • 2.2 Removing and installing particulate filter
    154
  • 3 Exhaust gas temperature regulation
    158
  • 3.1 Assembly overview - exhaust gas temperature regulation
    158
  • 4 Exhaust gas recirculation
    159
  • 4.1 Assembly overview - exhaust gas recirculation
    159
  • 4.2 Assembly overview - exhaust gas recirculation cooler
    160
  • Glow plug system
    162
  • 1 Glow plug system
    162
  • 1.1 Handling ceramic glow plugs
    162
  • 1.2 Removing and installing ceramic glow plugs
    162
  • 1.3 Removing and installing engine speed sender G28
    164
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 2-valve, TDI)
Manufacturer Volkswagen
Suitable for Caddy (2004 - 2010)
Suitable car types 2K
Engine code BMM
Category Reparaturanleitung

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