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

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

For Caddy

Original Volkswagen repair manual


14,00 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

3.218 KB

164 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, Injectors and Intake manifold. 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 measures when working on fuel supply
    2
  • 2.2 Safety precautions when working on injection system
    3
  • 2.4 Safety precautions when working on the cooling system
    4
  • 3 Repair instructions
    5
  • 3.1 Rules for cleanliness when working on fuel supply system
    5
  • 3.2 Foreign objects in engine
    5
  • 3.3 General notes on cooling system
    5
  • 3.4 General notes on fuel supply system
    6
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Securing engine on engine and gearbox support
    13
  • 1.3 Installing engine
    15
  • 2 Assembly mountings
    18
  • 2.1 Assembly overview - assembly mountings
    18
  • Crankshaft group
    20
  • 1 Cylinder block (pulley end)
    20
  • 1.1 Assembly overview - poly V-belt drive, vehicles with air conditioning system
    20
  • 1.3 Assembly overview - cylinder block
    22
  • 1.4 Removing and installing poly-V belt
    23
  • 1.5 Renewing crankshaft oil seal - belt pulley end
    24
  • 1.6 Removing and installing sealing flange on pulley end
    26
  • 2 Cylinder block, gearbox end
    30
  • 2.1 Assembly overview - cylinder block, gearbox end
    30
  • 2.2 Renewing crankshaft sealing flange - flywheel end
    31
  • 3 Crankshaft
    40
  • 3.1 Assembly overview - crankshaft
    40
  • 3.2 Crankshaft dimensions
    40
  • 4 Pistons and conrods
    42
  • 4.1 Assembly overview - pistons and conrods
    42
  • 4.2 Checking pistons and cylinder bores
    44
  • 4.3 Measuring piston projection at TDC
    45
  • 4.4 Piston and cylinder dimensions
    46
  • Cylinder head, valve gear
    47
  • 1 Cylinder head
    47
  • 1.1 Assembly overview - cylinder head
    47
  • 1.2 Removing and installing cylinder head
    50
  • 1.3 Removing and installing cylinder head cover
    56
  • 1.4 Cylinder head gasket identification
    58
  • 1.5 Checking compression
    58
  • 2 Toothed belt drive
    60
  • 2.1 Assembly overview - toothed belt
    60
  • 2.2 Removing and installing toothed belt
    61
  • 3 Valve gear
    77
  • 3.1 Assembly overview - valve gear
    77
  • 3.2 Measuring axial play of camshaft
    79
  • 3.3 Removing and installing camshaft oil seal
    79
  • 3.4 Removing and installing camshaft
    81
  • 3.5 Renewing valve stem seals
    86
  • 4 Inlet and exhaust valves
    89
  • 4.1 Checking valve guides
    89
  • Lubrication
    90
  • 1 Sump, oil pump
    90
  • 1.1 Assembly overview - sump/oil pump
    90
  • 1.2 Removing and installing sump
    91
  • 1.3 Engine oil:
    94
  • 2 Oil filter, oil pressure switch
    95
  • 2.1 Assembly overview - oil filter housing, oil pressure switch
    95
  • 2.2 Checking oil pressure and oil pressure switch
    96
  • 2.3 Measuring oil consumption
    97
  • Cooling
    98
  • 1 Cooling system/coolant
    98
  • 1.1 Coolant hose schematic diagram, engine code BDJ
    98
  • 1.2 Checking cooling system for leaks
    100
  • 1.3 Draining and adding coolant
    101
  • 1.4 Checking engine oil cooler for leaks
    110
  • 2 Coolant pump, regulation of cooling system
    112
  • 2.1 Assembly overview - coolant pump and thermostat, engine code BDJ
    112
  • 2.2 Removing and installing coolant pump
    116
  • 2.3 Removing and installing thermostat
    117
  • 3 Radiator, radiator fan
    120
  • 3.1 Assembly overview - radiator, radiator fan
    120
  • 3.2 Removing and installing radiator
    122
  • 3.3 Removing and installing fan mounting with fans
    123
  • Mixture preparation - injection
    125
  • 1 Injectors
    125
  • 1.1 Assembly overview - unit injector
    125
  • 1.2 Removing and installing unit injector
    126
  • 1.3 Renewing O-rings for unit injectors
    128
  • 1.4 Removing and installing prewiring for unit injectors
    130
  • 2 Vacuum system
    134
  • 2.1 Vacuum hose schematic diagram
    134
  • 2.2 Exhaust gas recirculation valve N18 schematic diagram
    135
  • 3 Air filter
    136
  • 3.1 Assembly overview - air filter housing, engine code BDJ
    136
  • 4 Intake manifold
    138
  • 4.1 Assembly overview - intake manifold, engine code BDJ
    138
  • 5 Engine control unit
    140
  • 5.1 Removing and installing engine control unit
    140
  • 6 High-pressure pump
    142
  • 6.1 Removing and installing tandem pump
    142
  • 6.2 Checking delivery pressure of tandem pump
    144
  • 6.3 Checking for internal leaks
    146
  • Exhaust system
    148
  • 1 Exhaust pipes and silencers
    148
  • 1.1 Assembly overview - silencers
    148
  • 1.2 Separating exhaust pipes from silencers
    149
  • 1.3 Aligning exhaust system free of stress
    149
  • 1.4 Installation position of clamps
    150
  • 2 Exhaust manifold
    151
  • 2.1 Assembly overview - exhaust manifold with catalytic converter
    151
  • 3 Exhaust gas recirculation
    152
  • 3.1 Assembly overview - exhaust gas recirculation, engine code BDJ
    152
  • 3.2 Checking exhaust gas recirculation valve
    154
  • Glow plug system
    156
  • 1 Glow plug system
    156
  • 1.1 Removing, installing and checking glow plugs
    156
  • 1.2 Removing and installing engine speed sender G28
    157
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, 2 valve)
Manufacturer Volkswagen
Suitable for Caddy (2004 - 2010)
Suitable car types 2K
Engine code BDJ
Category Reparaturanleitung

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