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

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

For Caddy

Original Volkswagen repair manual


34,16 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

21.449 KB

470 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Engine cover panel, Cylinder block (pulley end), Crankshaft, Pistons and conrods, 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 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 regulations for working on fuel supply
    2
  • 2.2 Safety precautions when working on fuel system
    2
  • 2.3 Safety precautions when working on the cooling system
    3
  • 3 Repair instructions
    5
  • 3.1 Rules for cleanliness
    5
  • 3.2 General repair instructions
    6
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Separating engine and gearbox
    23
  • 1.3 Securing engine on engine and gearbox support
    28
  • 1.4 Installing engine
    29
  • 2 Assembly mountings
    34
  • 2.1 Assembly overview - assembly mountings
    34
  • 2.2 Removing and installing engine mounting
    38
  • 2.3 Supporting engine in installation position
    41
  • 2.4 Adjusting assembly mountings
    43
  • 3 Engine cover panel
    49
  • 3.1 Removing and installing engine cover
    49
  • Crankshaft group
    51
  • 1 Cylinder block (pulley end)
    51
  • 1.1 Assembly overview - poly V-belt drive
    51
  • 1.2 Assembly overview - cylinder block (pulley end)
    53
  • 1.3 Assembly overview - sealing flange, belt pulley end
    56
  • 1.4 Removing and installing poly-V belt
    57
  • 1.5 Removing and installing tensioner for poly V-belt
    60
  • 1.6 Removing and installing bracket for ancillaries
    62
  • 1.7 Removing and installing vibration damper
    65
  • 1.8 Removing and installing engine bracket
    66
  • 1.9 Renewing crankshaft oil seal - belt pulley end
    70
  • 1.10 Removing and installing sealing flange on pulley end
    72
  • 2 Cylinder block, gearbox end
    78
  • 2.1 Assembly overview - cylinder block, gearbox end
    78
  • 2.2 Removing and installing flywheel
    79
  • 2.3 Removing and installing sealing flange on gearbox side
    80
  • 3 Crankshaft
    91
  • 3.1 Assembly overview - crankshaft
    91
  • 3.2 Crankshaft dimensions
    92
  • 3.3 Measuring axial clearance of crankshaft
    93
  • 3.4 Measuring radial clearance of crankshaft
    94
  • 3.5 Renewing needle bearing in crankshaft
    94
  • 4 Pistons and conrods
    97
  • 4.1 Assembly overview - pistons and conrods
    97
  • 4.2 Measuring piston projection at TDC
    100
  • 4.3 Checking pistons and cylinder bores
    101
  • 4.4 Separating new conrod
    104
  • 4.5 Checking radial clearance of conrods
    104
  • 4.6 Removing and installing oil spray jets
    105
  • Cylinder head, valve gear
    107
  • 1 Cylinder head
    107
  • 1.1 Assembly overview - cylinder head
    107
  • 1.2 Assembly overview - cylinder head cover
    111
  • 1.3 Removing and installing cylinder head
    113
  • 1.4 Removing and installing cylinder head cover
    130
  • 1.5 Removing and installing injector seals
    133
  • 1.6 Removing and installing vacuum pump
    136
  • 1.7 Checking compression
    137
  • 2 Fully enclosing toothed belt guard
    140
  • 2.1 Assembly overview - fully enclosing toothed belt guard
    140
  • 2.2 Removing and installing upper toothed belt guard (fully enclosing)
    142
  • 2.3 Removing and installing lower toothed belt guard (fully enclosed)
    143
  • 2.4 Removing and installing rear toothed belt guard (fully enclosing)
    144
  • 3 Toothed belt drive
    149
  • 3.1 Assembly overview - toothed belt
    149
  • 3.2 Removing and installing toothed belt
    152
  • 4 Valve gear
    170
  • 4.1 Assembly overview - valve gear
    170
  • 4.2 Measuring axial play of camshaft
    173
  • 4.3 Measuring radial play of camshaft
    175
  • 4.4 Removing and installing camshaft
    175
  • 4.5 Removing and installing camshaft oil seal
    185
  • 4.6 Checking hydraulic compensation elements
    191
  • 4.7 Removing and installing valve stem seals
    192
  • 5 Inlet and exhaust valves
    201
  • 5.1 Reworking valve seats
    201
  • 5.2 Checking valve guides
    201
  • 5.3 Checking valves
    202
  • 5.4 Valve dimensions
    203
  • Lubrication
    204
  • 1 Sump, oil pump
    204
  • 1.1 Assembly overview - sump/oil pump
    204
  • 1.2 Engine oil:
    207
  • 1.3 Removing and installing oil sump
    208
  • 1.4 Removing and installing oil pump
    213
  • 1.5 Removing and installing oil level and oil temperature sender G266
    214
  • 2 Engine oil cooler
    216
  • 2.1 Removing and installing engine oil cooler
    216
  • 2.2 Checking engine oil cooler for leaks
    220
  • 3 Oil filter, oil pressure switch
    223
  • 3.1 Assembly overview - oil filter housing, oil pressure switch
    223
  • 3.2 Removing and installing oil pressure switch F1
    225
  • 3.3 Checking oil pressure and oil pressure switch
    226
  • 3.4 Removing and installing oil filter housing
    228
  • 4 Oil circuit
    233
  • 4.1 Assembly overview - oil circuit
    233
  • 4.2 Removing and installing oil supply line
    233
  • Cooling
    240
  • 1 Cooling system/coolant
    240
  • 1.1 Connection diagram - coolant hoses
    240
  • 1.2 Checking cooling system for leaks
    241
  • 1.3 Draining and adding coolant
    244
  • 2 Coolant pump, regulation of cooling system
    254
  • 2.1 Assembly overview - coolant pump, thermostat
    254
  • 2.2 Removing and installing coolant circulation pump 2 V178
    254
  • 2.3 Removing and installing coolant pump
    257
  • 2.4 Removing and installing 4/2-way valve with thermostat
    258
  • 2.5 Removing and installing coolant temperature sender G62
    261
  • 2.6 Removing and installing radiator outlet coolant temperature sender G83
    262
  • 3 Coolant pipes
    265
  • 3.1 Assembly overview - coolant pipes
    265
  • 3.2 Removing and installing coolant pipes
    267
  • 3.3 Removing and installing upper coolant pipes
    277
  • 4 Radiator, radiator fan
    279
  • 4.1 Assembly overview - radiator/radiator fan
    279
  • 4.2 Removing and installing radiator
    281
  • 4.3 Removing and installing radiator cowl with radiator fan
    282
  • 4.4 Removing and installing radiator fan VX57
    283
  • 4.5 Removing and installing radiator fan 2 V177
    284
  • Turbocharging/supercharging
    286
  • 1 Turbocharger
    286
  • 1.1 Assembly overview - turbocharger
    286
  • 1.2 Removing and installing turbocharger
    290
  • 1.3 Renewing vacuum unit for turbocharger
    297
  • 2 Charge air system
    306
  • 2.1 Assembly overview - charge air system
    306
  • 2.2 Assembly overview - charge-air hose connections
    308
  • 2.3 Removing and installing charge air cooler
    310
  • 2.4 Removing and installing air pipe
    312
  • 2.6 Checking charge air system for leaks
    315
  • Mixture preparation - injection
    319
  • 1 Injection system
    319
  • 1.1 Schematic overview - fuel system
    319
  • 1.2 Overview of fitting locations - injection system
    321
  • 1.3 Filling/bleeding fuel system
    331
  • 1.4 Checking fuel system for leaks
    332
  • 2 Vacuum system
    334
  • 2.1 Connection diagram – vacuum system
    334
  • 2.2 Checking vacuum system
    335
  • 2.3 Removing and installing charge pressure control solenoid valve N75
    344
  • 3 Injectors/high-pressure accumulator (rail)
    347
  • 3.1 Assembly overview - injectors
    347
  • 3.2 Adapting correction values for injectors
    350
  • 3.3 Testing injectors
    351
  • 3.4 Checking return flow rate of injectors with engine running
    351
  • 3.5 Checking return flow rate of injectors at starter speed
    354
  • 3.6 Testing jammed-open injectors
    356
  • 3.7 Removing and installing injectors
    358
  • 3.8 Removing and installing high-pressure lines
    363
  • 3.9 Removing and installing fuel rail
    369
  • 4 Air filter
    375
  • 4.1 Assembly overview - air filter housing
    375
  • 4.2 Removing and installing air filter housing
    377
  • 5 Intake manifold
    380
  • 5.1 Assembly overview – intake manifold
    380
  • 5.2 Removing and installing intake manifold
    382
  • 5.3 Removing and installing throttle valve module GX3
    386
  • 6 Senders and sensors
    389
  • 6.1 Removing and installing exhaust gas pressure sensor 1 G450
    389
  • 6.2 Removing and installing air mass meter G70
    390
  • 6.3 Checking fuel pressure regulating valve N276
    391
  • 6.4 Removing and installing fuel pressure regulating valve N276
    392
  • 6.5 Removing and installing fuel pressure sender G247
    396
  • 7 Engine control unit
    399
  • 7.1 Removing and installing engine control unit J623
    399
  • 7.2 Removing and installing engine (motor) control unit J623 with protective housing
    401
  • 8 High-pressure pump
    405
  • 8.1 Assembly overview - high-pressure pump
    405
  • 8.2 Removing and installing high-pressure pump
    407
  • 8.3 Checking high-pressure pump
    411
  • 9 Lambda probe
    414
  • 9.1 Removing and installing Lambda probe
    414
  • Exhaust system
    416
  • 1 Exhaust pipes and silencers
    416
  • 1.1 Assembly overview – silencers
    416
  • 1.2 Separating exhaust pipes from silencers
    417
  • 1.3 Aligning exhaust system free of stress
    419
  • 1.4 Installation position of clamp
    420
  • 2 Emission control
    422
  • 2.1 Assembly overview – emission control
    422
  • 2.2 Removing and installing particulate filter
    425
  • 3 Exhaust gas temperature regulation
    436
  • 3.1 Assembly overview – exhaust gas temperature regulation
    436
  • 3.2 Removing and installing exhaust gas temperature sender 1 G235
    437
  • 3.3 Removing and installing exhaust gas temperature sender 3 G495
    438
  • 3.4 Removing and installing exhaust gas temperature sender 4 G648
    440
  • 4 Exhaust gas recirculation
    443
  • 4.1 Assembly overview – exhaust gas recirculation
    443
  • 4.2 Removing and installing exhaust gas recirculation cooler
    445
  • 4.3 Checking changeover for exhaust gas recirculation cooler
    448
  • 4.4 Checking exhaust gas recirculation cooler for leaks
    449
  • 4.5 Cleaning exhaust gas recirculation system
    449
  • Glow plug system
    459
  • 1 Glow plug system
    459
  • 1.1 Removing and installing glow plug
    459
  • 1.2 Removing and installing automatic glow period control unit J179
    461
  • 1.3 Removing and installing engine speed sender G28
    461
  • 1.4 Removing and installing Hall sender G40
    462
Manufacturer's designation 4-cylinder diesel engine (2.0 l engine, common rail, generation II)
Manufacturer Volkswagen
Suitable for Caddy (2016)
Suitable car types SA
Engine code CLCA, CFHF, CLCB
Category Reparaturanleitung

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