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

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

For Caddy KA / Caddy Maxi

Original Volkswagen repair manual


30,13 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

20.357 KB

400 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Pistons and conrods, Crankshaft, 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
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Repair manual Caddy KA / Caddy Maxi 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
    3
  • 2.1 Safety measures when working on fuel supply
    3
  • 2.2 Safety precautions when working on injection system
    4
  • 2.3 Safety precautions when working on the cooling system
    4
  • 2.4 Safety precautions when working on charge air system
    6
  • 2.5 General safety provisions
    6
  • 3 Repair instructions
    7
  • 3.1 General notes on the lubrication system
    7
  • 3.2 Rules for cleanliness when working on fuel supply system or injection system
    7
  • 3.3 Rules for cleanliness during work on fuel system
    8
  • 3.4 General repair notes for working on fuel systems
    8
  • Removing and installing engine
    11
  • 1 Removing and installing engine
    11
  • 1.1 Removing engine
    11
  • 1.2 Separating engine from gearbox
    23
  • 1.3 Separating engine from dual clutch gearbox
    25
  • 1.4 Securing engine on engine and gearbox support
    27
  • 1.5 Installing engine
    28
  • 2 Assembly mountings
    32
  • 2.1 Assembly overview - assembly mountings
    32
  • 2.2 Removing and installing engine mounting
    35
  • 2.3 Supporting engine in installation position
    37
  • 2.4 Adjusting assembly mountings
    39
  • 3 Engine cover panel
    43
  • 3.1 Removing and installing engine cover
    43
  • Crankshaft group
    44
  • 1 Cylinder block (pulley end)
    44
  • 1.1 Assembly overview - crankcase
    44
  • 1.2 Assembly overview - ancillary bracket
    46
  • 1.3 Assembly overview - sealing flange, belt pulley end
    46
  • 1.4 Assembly overview - poly V-belt drive with air conditioning compressor
    48
  • 1.5 Assembly overview - poly V-belt drive without air conditioner compressor
    49
  • 1.6 Removing and installing poly V-belt, vehicles with air conditioner
    49
  • 1.7 Removing and installing tensioner for poly V-belt
    51
  • 1.8 Removing and installing bracket for ancillaries
    52
  • 1.9 Removing and installing vibration damper
    54
  • 1.10 Removing and installing engine bracket
    55
  • 1.11 Renewing crankshaft oil seal - belt pulley end
    59
  • 1.12 Removing and installing sealing flange on pulley end
    61
  • 2 Cylinder block, gearbox end
    65
  • 2.1 Assembly overview - cylinder block, gearbox end
    65
  • 2.2 Removing and installing flywheel
    66
  • 2.3 Removing and installing sealing flange on gearbox side
    67
  • 3 Pistons and conrods
    75
  • 3.1 Assembly overview - pistons and conrods
    75
  • 3.2 Checking pistons and cylinder bores
    77
  • 3.3 Piston and cylinder dimensions
    78
  • 3.4 Measuring piston projection at TDC
    78
  • 3.5 Checking radial clearance of conrods
    80
  • 3.6 Separating new conrods
    81
  • 3.7 Removing and installing oil spray jets
    81
  • 4 Crankshaft
    83
  • 4.1 Assembly overview - crankshaft
    83
  • 4.2 Crankshaft dimensions
    84
  • 4.3 Measuring axial clearance of crankshaft
    84
  • 4.4 Measuring radial clearance of crankshaft
    85
  • 4.5 Renewing needle bearing in crankshaft
    85
  • 4.6 Renewing spur gear for crankshaft
    87
  • Cylinder head, valve gear
    91
  • 1 Cylinder head
    91
  • 1.1 Assembly overview - cylinder head
    91
  • 1.2 Assembly overview - cylinder head cover
    93
  • 1.3 Removing and installing cylinder head
    96
  • 1.4 Removing and installing cylinder head cover
    108
  • 1.5 Removing and installing vacuum pump
    111
  • 1.6 Checking compression
    112
  • 2 Fully enclosing toothed belt guard
    114
  • 2.1 Assembly overview - fully enclosing toothed belt guard
    114
  • 2.2 Removing and installing upper toothed belt guard (fully enclosing)
    115
  • 2.3 Removing and installing lower toothed belt guard (fully enclosed)
    116
  • 2.4 Removing and installing rear toothed belt guard (fully enclosing)
    117
  • 3 Toothed belt drive
    122
  • 3.1 Assembly overview - toothed belt drive
    122
  • 3.2 Removing and installing toothed belt
    124
  • 4 Valve gear
    138
  • 4.1 Assembly overview - valve gear
    138
  • 4.2 Measuring axial clearance of camshaft
    141
  • 4.3 Measuring radial clearance of camshafts
    142
  • 4.4 Removing and installing camshafts
    143
  • 4.5 Removing and installing camshaft oil seal
    149
  • 4.6 Checking hydraulic compensation elements
    154
  • 4.7 Renewing valve stem seals with cylinder head installed
    154
  • 4.8 Renewing valve stem seals with cylinder head removed
    157
  • 5 Inlet and exhaust valves
    162
  • 5.1 Reworking valve seats
    162
  • 5.2 Checking valve guides
    162
  • 5.3 Checking valves
    163
  • 5.4 Valve dimensions
    163
  • Lubrication
    164
  • 1 Sump, oil pump
    164
  • 1.1 Assembly overview - sump/oil pump
    164
  • 1.2 Removing and installing sump
    166
  • 1.3 Removing and installing oil pump
    170
  • 1.4 Removing and installing oil pump, with balancer shaft module
    171
  • 1.5 Engine oil:
    172
  • 1.6 Removing and installing oil level and oil temperature sender G266
    172
  • 2 Oil filter, oil pressure switch
    174
  • 2.1 Assembly overview - oil filter housing with engine oil cooler
    174
  • 2.2 Removing and installing oil filter housing with engine oil cooler
    175
  • 2.3 Removing and installing oil pressure switch F1
    179
  • 2.4 Checking oil pressure switch F1
    180
  • 2.5 Checking oil pressure
    181
  • 2.6 Measuring oil consumption
    182
  • 3 Engine oil cooler
    183
  • 3.1 Removing and installing engine oil cooler
    183
  • 4 Balancer shaft module
    187
  • 4.1 Assembly overview - balancer shaft module
    187
  • 4.2 Removing balancer shaft module
    190
  • 4.3 Installing a new balancer shaft module
    192
  • 4.4 Installing a previously used balancer shaft module again
    196
  • 5 Oil circuit
    198
  • 5.1 Assembly overview - oil circuit
    198
  • 5.2 Removing and installing oil line for turbocharger
    199
  • Cooling
    204
  • 1 Cooling system/coolant
    204
  • 1.1 Coolant hose schematic diagram
    204
  • 1.2 Coolant hose connection diagram, gearbox side
    205
  • 1.3 Draining and adding coolant
    206
  • 1.4 Checking cooling system for leaks
    214
  • 1.5 Checking engine oil cooler for leaks
    216
  • 2 Coolant pump, regulation of cooling system
    219
  • 2.1 Assembly overview - coolant pump, thermostat
    219
  • 2.2 Removing and installing coolant pump
    219
  • 2.3 Removing and installing 4/2-way valve with thermostat
    220
  • 2.4 Removing and installing coolant temperature sender G62
    223
  • 2.5 Removing and installing radiator outlet coolant temperature sender G83
    225
  • 2.6 Removing and installing coolant circulation pump 2 V178
    226
  • 3 Radiator, radiator fan
    229
  • 3.1 Assembly overview - radiator/radiator fan
    229
  • 3.2 Removing and installing radiator
    230
  • 3.3 Removing and installing radiator cowl with radiator fan
    231
  • 4 Coolant pipes
    233
  • 4.1 Assembly overview - coolant pipes
    233
  • 4.2 Removing and installing front coolant pipe
    234
  • 4.3 Removing and installing upper front coolant pipe
    238
  • 4.4 Removing and installing left coolant pipe
    239
  • 4.5 Removing and installing right coolant pipe
    241
  • Turbocharging/supercharging
    244
  • 1 Charge air system
    244
  • 1.1 Assembly overview - charge air system
    244
  • 1.2 Assembly overview - charge-air hose connections
    245
  • 1.3 Hose connections with screw-type clips
    246
  • 1.4 Removing and installing charge air cooler
    246
  • 1.5 Removing and installing charge air pipe
    248
  • 1.6 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
    249
  • 1.7 Checking charge air system for leaks
    250
  • 2 Turbocharger
    254
  • 2.1 Assembly overview - turbocharger
    254
  • 2.2 Removing and installing turbocharger
    258
  • 2.3 Replacing vacuum unit with position sender for charge pressure positioner G581
    263
  • 2.4 Removing and installing charge pressure control solenoid valve N75
    269
  • Mixture preparation - injection
    272
  • 1 Injection system
    272
  • 1.1 Schematic overview - fuel system
    272
  • 1.2 Overview of fitting locations - injection system
    274
  • 1.3 Checking fuel system for leaks
    282
  • 1.4 Filling and bleeding fuel system
    282
  • 2 Vacuum system
    284
  • 2.1 Connection diagram - vacuum system
    284
  • 2.2 Checking vacuum system
    285
  • 3 Injectors/high-pressure accumulator (rail)
    293
  • 3.1 Assembly overview - fuel rail and injectors
    293
  • 3.2 Adapting correction values for injectors
    295
  • 3.3 Testing injectors
    296
  • 3.4 Checking return flow rate of injectors with engine running
    296
  • 3.5 Checking return flow rate of injectors at starter speed
    299
  • 3.6 Checking for injectors sticking open
    300
  • 3.7 Checking low pressure fuel system
    302
  • 3.8 Removing and installing injectors
    303
  • 3.9 Removing and installing high-pressure lines
    309
  • 3.10 Removing and installing fuel rail
    314
  • 3.11 Removing and installing injector seal in cylinder head cover
    318
  • 4 High-pressure pump
    321
  • 4.1 Assembly overview - high-pressure pump
    321
  • 4.2 Removing and installing high-pressure pump
    322
  • 4.3 Checking high-pressure pump
    325
  • 5 Intake manifold
    328
  • 5.1 Assembly overview - intake manifold
    328
  • 5.2 Removing and installing intake manifold
    329
  • 5.3 Removing and installing throttle valve module GX3
    332
  • 6 Senders and sensors
    335
  • 6.1 Removing and installing exhaust gas pressure sensor 1 G450
    335
  • 6.2 Removing and installing air mass meter G70
    336
  • 6.3 Checking fuel pressure regulating valve N276
    337
  • 6.4 Removing and installing fuel pressure regulating valve N276
    338
  • 6.5 Removing and installing fuel pressure sender G247
    342
  • 7 Lambda probe
    346
  • 7.1 Removing and installing Lambda probe G39
    346
  • 8 Air filter
    348
  • 8.1 Assembly overview - air filter housing
    348
  • 8.2 Removing and installing air filter housing
    349
  • 9 Engine control unit
    351
  • 9.1 Removing and installing engine control unit J623
    351
  • 9.2 Removing and installing anti-theft engine control unit J623
    352
  • Exhaust system
    355
  • 1 Exhaust pipes and silencers
    355
  • 1.1 Assembly overview - silencers
    355
  • 1.2 Cutting exhaust pipe
    356
  • 1.3 Aligning exhaust system free of stress
    357
  • 1.4 Installation position of clamp
    358
  • 2 Emission control
    359
  • 2.1 Assembly overview - particulate filter
    359
  • 2.2 Assembly overview - catalytic converter
    360
  • 2.3 Removing and installing particulate filter
    361
  • 3 Exhaust gas temperature regulation
    370
  • 3.1 Assembly overview - exhaust gas temperature regulation
    370
  • 3.2 Removing and installing exhaust gas temperature sender 1 G235
    371
  • 3.3 Removing and installing exhaust gas temperature sender 3 G495
    372
  • 3.4 Removing and installing exhaust gas temperature sender 4 G648
    374
  • 4 Exhaust gas recirculation
    376
  • 4.1 Assembly overview - exhaust gas recirculation
    376
  • 4.2 Removing and installing exhaust gas recirculation cooler
    377
  • 4.3 Checking changeover for exhaust gas recirculation cooler
    379
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    380
  • 4.5 Cleaning exhaust gas recirculation system
    381
  • Glow plug system
    388
  • 1 Glow plug system
    388
  • 1.1 Removing and installing glow plug
    388
  • 1.2 Removing and installing automatic glow period control unit J179
    390
  • 1.3 Removing and installing engine speed sender G28
    390
  • 1.4 Removing and installing Hall sender G40
    391
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail)
Manufacturer Volkswagen
Suitable for Caddy KA / Caddy Maxi (2011)
Suitable car types 2C
Engine code CFJA, CLCA, CFHE, CFHF, CLCB
Category Reparaturanleitung

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