Name: 4-cylinder diesel engine (2.0 l engine, common rail)
Brand: Volkswagen
SKU: CDGe1b3ee96bf07
Price: 30.13 EUR
Availability: InStock

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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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