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

Original Volkswagen repair manual


25,38 €7% VAT incl.

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  • English

Immediately available for download

Language: English

Digital PDF file

34.172 KB

325 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, Engine oil cooler, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Turbocharger and Lambda probe. Show more
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Repair manual Caddy 4-cylinder injection engine PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Safety information
    1
  • 1.1 Safety regulations for working on fuel supply
    1
  • 1.2 Safety measures when working on vehicles with start/stop system
    1
  • 1.4 Safety precautions when working on the cooling system
    2
  • 1.5 Safety precautions when working on ignition system
    2
  • 1.6 Safety precautions when working on exhaust system
    3
  • 2 Identification
    4
  • 2.1 Engine number/engine data
    4
  • 3 Repair instructions
    6
  • 3.1 Rules for cleanliness
    6
  • 3.2 General information
    7
  • 3.3 Foreign objects in engine
    7
  • 3.4 Contact corrosion
    8
  • 3.5 Routing and attachment of lines
    8
  • 3.6 Fitting radiator and condensers
    8
  • 3.7 Checking vacuum system
    8
  • Removing and installing engine
    10
  • 1 Removing and installing engine
    10
  • 1.1 Removing engine
    10
  • 1.2 Separating engine and gearbox
    20
  • 1.3 Securing engine on engine and gearbox support
    24
  • 1.4 Installing engine
    26
  • 2 Assembly mountings
    31
  • 2.1 Assembly overview - assembly mountings
    31
  • 2.2 Removing and installing engine mounting
    33
  • 2.3 Removing and installing gearbox mounting
    35
  • 2.4 Removing and installing pendulum support
    36
  • 2.5 Supporting engine in installation position
    38
  • 2.6 Adjusting assembly mountings
    41
  • 2.7 Checking adjustment of assembly mountings
    43
  • Crankshaft group
    45
  • 1 Cylinder block (pulley end)
    45
  • 1.1 Assembly overview - poly V-belt drive
    45
  • 1.2 Assembly overview - sealing flange, belt pulley end
    49
  • 1.3 Removing and installing poly-V belt
    51
  • 1.4 Removing and installing tensioner for poly V-belt
    54
  • 1.5 Removing and installing vibration damper
    55
  • 1.6 Removing and installing engine support
    57
  • 1.7 Renewing crankshaft oil seal - belt pulley end
    60
  • 1.8 Removing and installing sealing flange on pulley end
    63
  • 2 Cylinder block, gearbox end
    64
  • 2.1 Assembly overview - cylinder block, gearbox end
    64
  • 2.2 Removing and installing flywheel
    65
  • 2.3 Removing and installing sealing flange on gearbox side
    66
  • 3 Crankshaft
    77
  • 3.1 Crankshaft dimensions
    77
  • 3.2 Renewing needle bearing in crankshaft
    77
  • 3.3 Measuring axial clearance of crankshaft
    80
  • 4 Pistons and conrods
    82
  • 4.1 Assembly overview - pistons and conrods
    82
  • 4.2 Removing and installing pistons
    85
  • 4.3 Checking pistons and cylinder bores
    86
  • 4.4 Separating new conrod
    88
  • 4.5 Checking radial clearance of conrods
    89
  • 4.6 Removing and installing oil spray jets
    89
  • Cylinder head, valve gear
    91
  • 1 Cylinder head
    91
  • 1.1 Assembly overview - cylinder head
    91
  • 1.2 Assembly overview - camshaft housing
    94
  • 1.3 Removing and installing cylinder head
    97
  • 1.4 Removing and installing camshaft housing
    102
  • 1.5 Checking compression
    106
  • 2 Toothed belt drive
    109
  • 2.1 Assembly overview - toothed belt cover
    109
  • 2.2 Assembly overview - toothed belt
    109
  • 2.3 Removing and installing toothed belt
    111
  • 2.4 Checking valve timing
    119
  • 2.5 Removing toothed belt from camshaft
    125
  • 3 Valve gear
    133
  • 3.1 Assembly overview - valve gear
    133
  • 3.2 Measuring axial play of camshaft
    135
  • 3.3 Removing and installing camshaft oil seal
    136
  • 3.4 Removing and installing camshaft adjuster
    144
  • 3.5 Removing and installing camshaft control valve 1 N205
    146
  • 3.6 Removing and installing valve stem seals
    146
  • 4 Inlet and exhaust valves
    156
  • 4.1 Reworking valve seats
    156
  • 4.2 Checking valve guides
    158
  • 4.3 Checking valves
    159
  • 4.4 Valve dimensions
    159
  • Lubrication
    160
  • 1 Sump, oil pump
    160
  • 1.1 Assembly overview - sump/oil pump
    160
  • 1.2 Engine oil:
    164
  • 1.3 Removing and installing oil sump
    165
  • 1.4 Removing and installing oil pump
    171
  • 1.5 Removing and installing oil level and oil temperature sender G266
    173
  • 2 Engine oil cooler
    175
  • 2.1 Assembly overview - engine oil cooler
    175
  • 2.2 Removing and installing engine oil cooler
    175
  • 3 Crankcase ventilation
    177
  • 3.1 Assembly overview - crankcase breather system
    177
  • 3.2 Removing and installing oil separator
    178
  • 4 Oil filter, oil pressure switch
    182
  • 4.1 Assembly overview - oil filter/oil pressure switch
    182
  • 4.2 Removing and installing oil pressure switch for reduced oil pressure F378
    183
  • 4.3 Checking oil pressure and oil pressure switch
    184
  • Cooling
    186
  • 1 Cooling system/coolant
    186
  • 1.1 Connection diagram - coolant hoses
    186
  • 1.2 Checking cooling system for leaks
    188
  • 1.3 Draining and adding coolant
    190
  • 2 Coolant pump, regulation of cooling system
    197
  • 2.1 Assembly overview - coolant pump, thermostat
    197
  • 2.2 Assembly overview - electric coolant pump
    200
  • 2.3 Assembly overview - coolant temperature sender
    201
  • 2.4 Removing and installing electric coolant pump
    202
  • 2.5 Removing and installing coolant pump
    204
  • 2.6 Removing and installing thermostat
    209
  • 2.7 Removing and installing toothed belt pulley for coolant pump
    213
  • 2.8 Removing and installing coolant temperature sender G62
    215
  • 2.9 Removing and installing radiator outlet coolant temperature sender G83
    217
  • 3 Coolant pipes
    219
  • 3.1 Assembly overview - coolant pipes
    219
  • 3.2 Removing and installing coolant pipes
    219
  • 4 Radiator, radiator fan
    224
  • 4.1 Assembly overview - radiator/radiator fan
    224
  • 4.2 Assembly overview – radiator cowl and radiator fan
    226
  • 4.3 Removing and installing radiator
    227
  • 4.4 Removing and installing radiator cowl with radiator fan
    231
  • 4.5 Removing and installing radiator fan VX57
    232
  • 4.6 Removing and installing radiator fan 2 V177
    233
  • Turbocharging/supercharging
    234
  • 1 Turbocharger
    234
  • 1.1 Assembly overview - turbocharger
    234
  • 1.2 Removing and installing turbocharger
    235
  • 1.3 Removing and installing charge pressure positioner V465
    239
  • 2 Charge air system
    241
  • 2.1 Assembly overview - charge air system
    241
  • 2.2 Removing and installing charge air cooler
    244
  • 2.4 Checking charge air system for leaks
    247
  • 2.5 Removing and installing air pipe
    250
  • Mixture preparation - injection
    253
  • 1 Injection system
    253
  • 1.1 Overview of fitting locations - injection system
    253
  • 2 Injectors
    257
  • 2.1 Assembly overview - fuel rail with injectors
    257
  • 2.2 Removing and installing fuel rail
    259
  • 2.3 Removing and installing injectors
    259
  • 2.4 Renewing seals on injectors
    264
  • 2.5 Cleaning injectors
    271
  • 3 Air filter
    273
  • 3.1 Assembly overview - air filter housing
    273
  • 3.2 Removing and installing air filter housing
    275
  • 4 Intake manifold
    276
  • 4.1 Assembly overview – intake manifold
    276
  • 4.2 Removing and installing intake manifold
    278
  • 4.3 Removing and installing throttle valve module GX3
    280
  • 4.4 Cleaning throttle valve module
    281
  • 5 Senders and sensors
    283
  • 5.1 Removing and installing fuel pressure sender G247
    283
  • 5.2 Checking fuel pressure sender G247
    284
  • 6 Engine control unit
    287
  • 6.1 Removing and installing engine (motor) control unit J623 with protective housing
    287
  • 7 High-pressure pump
    290
  • 7.1 Assembly overview - high-pressure pump
    290
  • 7.2 Removing and installing high-pressure pump
    291
  • 7.3 Removing and installing high-pressure pipe
    292
  • 8 Lambda probe
    294
  • 8.1 Assembly overview - Lambda probe
    294
  • 8.2 Removing and installing Lambda probe
    295
  • Exhaust system
    297
  • 1 Exhaust pipes and silencers
    297
  • 1.1 Assembly overview – silencers
    297
  • 1.2 Separating exhaust pipes from silencers
    298
  • 1.3 Aligning exhaust system free of stress
    300
  • 1.4 Checking exhaust system for leaks
    301
  • 1.5 Installation position of clamp
    301
  • 2 Emission control
    304
  • 2.1 Assembly overview – emission control
    304
  • 2.2 Removing and installing catalytic converter
    307
  • Ignition system
    311
  • 1 Ignition system
    311
  • 1.1 Assembly overview - ignition system
    311
  • 1.2 Test data, spark plugs
    312
  • 1.3 Removing and installing ignition coils with output stage
    313
  • 1.4 Removing and installing knock sensor 1 G61
    315
  • 1.5 Removing and installing Hall sender G40
    317
  • 1.6 Removing and installing engine speed sender G28
    317
Manufacturer's designation 4-cylinder injection engine (1.2 l direct injection engine, turbocharger)
Manufacturer Volkswagen
Suitable for Caddy (2016)
Suitable car types SA
Engine code CYVC
Category Reparaturanleitung

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