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  • Examplepage for repair manual 4-cylinder injection engine (1.2 l direct injection engine, turbocharger)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.2 l direct injection engine, turbocharger)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.2 l direct injection engine, turbocharger)

4-cylinder injection engine (1.2 l direct injection engine, turbocharger)

For Caddy KA / Caddy Maxi

Original Volkswagen repair manual


16,70 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

19.266 KB

201 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing engine, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Cover for timing chain, Chain drive, Valve gear, Sump, oil pump, Engine oil cooler, Oil filter, oil pressure switch, Coolant pump, regulation of cooling system, Radiator, radiator fan and Exhaust turbocharger. Show more
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Repair manual Caddy KA / Caddy Maxi 4-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety precautions when working on the cooling system
    1
  • 1.2 Safety regulations for working on fuel supply
    2
  • 1.3 Releasing high pressure in fuel system
    2
  • 1.4 Safety precautions when working on charge air system
    3
  • 1.5 Safety precautions when working on ignition system
    3
  • 1.6 Safety regulations for working on fuel supply
    4
  • 2 Identification
    6
  • 2.1 Engine number/engine data
    6
  • 3 General information
    7
  • 3.1 General notes on injection
    7
  • 4 Repair instructions
    8
  • 4.1 Rules for cleanliness when working on fuel supply system/injection system
    8
  • Removing and installing engine
    9
  • 1 Removing and installing engine
    9
  • 1.1 Removing engine
    9
  • 1.2 Securing engine on engine and gearbox support
    16
  • 1.3 Installing engine
    16
  • 2 Assembly mountings
    20
  • 2.1 Assembly overview - assembly mountings
    20
  • Crankshaft group
    21
  • 1 Cylinder block (pulley end)
    21
  • 1.1 Assembly overview - poly V-belt drive
    21
  • 1.2 Removing and installing poly V-belt, vehicles with air conditioner
    22
  • 1.3 Removing and installing poly V-belt, vehicles without air conditioner
    23
  • 1.4 Removing and installing top ancillary bracket
    24
  • 1.5 Removing and installing bottom ancillary bracket
    25
  • 1.6 Renewing crankshaft oil seal - belt pulley end
    26
  • 1.7 Removing and installing belt pulley
    29
  • 2 Cylinder block, gearbox end
    33
  • 2.1 Assembly overview - cylinder block, gearbox end
    33
  • 2.2 Removing and installing sealing flange on gearbox side
    34
  • 3 Crankshaft
    43
  • 3.1 Renewing needle bearing in crankshaft
    43
  • 3.2 Crankshaft dimensions
    44
  • 4 Pistons and conrods
    45
  • 4.1 Assembly overview - pistons and conrods
    45
  • 4.2 Checking pistons and cylinder bores
    46
  • 4.3 Separating new conrod
    47
  • 4.4 Piston and cylinder dimensions
    48
  • Cylinder head, valve gear
    49
  • 1 Cylinder head
    49
  • 1.1 Assembly overview - cylinder head
    49
  • 1.2 Removing and installing cylinder head cover with camshaft
    51
  • 1.3 Removing and installing cylinder head
    60
  • 1.4 Checking compression
    66
  • 2 Cover for timing chain
    68
  • 2.1 Removing and installing top valve timing housing
    68
  • 2.2 Removing and installing bottom valve timing housing
    71
  • 3 Chain drive
    74
  • 3.1 Assembly overview - timing chain
    74
  • 3.2 Checking timing chain
    77
  • 3.3 Removing and installing timing chain
    80
  • 3.4 Removing and installing timing chain and chain drive for oil pump
    87
  • 3.5 Checking valve timing
    90
  • 3.6 Adjusting valve timing
    93
  • 4 Valve gear
    101
  • 4.1 Assembly overview - valve gear
    101
  • 4.2 Measuring axial play of camshaft
    102
  • 4.3 Removing and installing valve stem seals
    103
  • 5 Inlet and exhaust valves
    105
  • 5.1 Reworking valve seats
    105
  • 5.2 Checking valve guides
    106
  • 5.3 Valve dimensions
    107
  • Lubrication
    108
  • 1 Sump, oil pump
    108
  • 1.1 Assembly overview - sump/oil pump
    108
  • 1.2 Engine oil:
    111
  • 1.3 Removing and installing oil sump
    111
  • 1.4 Removing and installing oil pump
    115
  • 2 Engine oil cooler
    118
  • 2.1 Removing and installing engine oil cooler
    118
  • 3 Crankcase ventilation
    120
  • 3.1 Assembly overview - crankcase breather system
    120
  • 3.2 Removing and installing oil separator
    121
  • 4 Oil filter, oil pressure switch
    123
  • 4.1 Checking oil pressure and oil pressure switch
    123
  • 4.2 Removing and installing non-return valve
    124
  • Cooling
    126
  • 1 Cooling system/coolant
    126
  • 1.1 Connection diagram - coolant hoses
    126
  • 1.2 Draining and adding coolant
    127
  • 1.3 Checking cooling system for leaks
    132
  • 2 Coolant pump, regulation of cooling system
    134
  • 2.1 Assembly overview - thermostat
    134
  • 2.2 Removing and installing coolant pump
    134
  • 2.3 Removing and installing coolant circulation pump V50
    136
  • 3 Radiator, radiator fan
    139
  • 3.1 Assembly overview - radiator/ radiator fan V7
    139
  • 3.2 Removing and installing radiator
    141
  • 3.3 Removing and installing radiator fan V7
    143
  • Turbocharging/supercharging
    145
  • 1 Exhaust turbocharger
    145
  • 1.1 Assembly overview - turbocharger
    145
  • 1.2 Removing and installing turbocharger
    147
  • 1.3 Removing and installing charge pressure positioner V465
    150
  • 2 Charge air system
    153
  • 2.1 Assembly overview - charge air system
    153
  • 2.2 Removing and installing charge air cooler
    154
  • Mixture preparation - injection
    157
  • 1 Injectors
    157
  • 1.1 Removing and installing injectors
    157
  • 1.2 Renewing seals on injectors
    159
  • 2 Air filter
    163
  • 2.1 Assembly overview - air filter
    163
  • 2.2 Removing and installing air filter
    163
  • 3 Intake manifold
    165
  • 3.1 Assembly overview - intake manifold, part I
    165
  • 3.2 Assembly overview - intake manifold, part II
    166
  • 3.3 Removing and installing intake manifold
    167
  • 3.4 Removing and installing throttle valve module J338
    168
  • 3.5 Cleaning throttle valve module J338
    171
  • 4 Senders and sensors
    172
  • 4.1 Checking fuel pressure sender G247
    172
  • 4.2 Checking fuel pressure regulator and holding pressure
    174
  • 5 Engine (motor) control unit
    178
  • 5.1 Removing and installing engine (motor) control unit J623
    178
  • 5.2 Removing and installing anti-theft engine control unit J623
    179
  • 6 High-pressure pump
    181
  • 6.1 Assembly overview - high-pressure pump
    181
  • 6.2 Removing and installing high-pressure pump
    182
  • Exhaust system
    185
  • 1 Exhaust pipes and silencers
    185
  • 1.1 Assembly overview - silencers
    185
  • 1.2 Separating exhaust pipes from silencers
    186
  • 1.3 Installation position of clamp
    187
  • 2 Exhaust gas cleaning
    189
  • 2.1 Assembly overview - emission control
    189
  • 2.2 Assembly overview- emission control, vehicles as of week 22/2011
    191
  • Ignition system
    193
  • 1 Ignition system
    193
  • 1.1 Assembly overview - ignition system
    193
  • 1.2 Test data, spark plugs
    194
  • 1.3 Removing and installing engine speed sender G28
    195
Manufacturer's designation 4-cylinder injection engine (1.2 l direct injection engine, turbocharger)
Manufacturer Volkswagen
Suitable for Caddy KA / Caddy Maxi (2011)
Suitable car types 2C
Engine code CBZA
Category Reparaturanleitung

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