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  • Examplepage for repair manual 4-cylinder injection engine (1.6 l engine, BiFuel)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l engine, BiFuel)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l engine, BiFuel)

4-cylinder injection engine (1.6 l engine, BiFuel)

For Caddy KA / Caddy Maxi

Original Volkswagen repair manual


15,60 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

5.260 KB

186 Sites

Detailed technical data

Immediately readable

This repair manual contains: Removing and installing motor, Assembly mountings, Cylinder block (pulley end), Crankshaft, Pistons and conrods, Toothed belt drive, Valve gear, Inlet and exhaust valves, Sump, oil pump, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Fuel, Fuel delivery unit, fuel gauge sender, Accelerator pedal, Activated charcoal filter system, Injectors and Intake manifold. 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 Identification
    1
  • 1.1 Engine number/engine data
    1
  • 2 Safety information
    2
  • 2.1 Safety precautions when working on the cooling system
    2
  • 2.2 Safety precautions when working on ignition system
    2
  • 2.4 Safety precautions when working on LPG system
    3
  • 2.5 Safety regulations for working on fuel supply
    4
  • 2.6 Safety precautions when working on injection system
    4
  • 3 Repair instructions
    6
  • 3.1 General notes on ignition system
    6
  • 3.2 General notes on injection
    6
  • 3.3 Foreign objects in engine
    7
  • 3.4 Rules for cleanliness when working on fuel supply system/injection system
    7
  • Removing and installing engine
    8
  • 1 Removing and installing motor
    8
  • 1.1 Removing motor
    8
  • 1.2 Securing engine on engine and gearbox support
    12
  • 1.3 Installing engine
    13
  • 2 Assembly mountings
    15
  • 2.1 Assembly overview – assembly mountings
    15
  • Crankshaft group
    16
  • 1 Cylinder block (pulley end)
    16
  • 1.1 Assembly overview - poly V-belt drive
    16
  • 1.2 Assembly overview - cylinder block
    18
  • 1.3 Removing and installing poly-V belt
    19
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    20
  • 1.5 Removing and installing sealing flange on pulley end
    23
  • 2 Cylinder block, gearbox end
    27
  • 2.1 Assembly overview - cylinder block, gearbox end
    27
  • 2.2 Removing and installing sealing flange on gearbox side
    28
  • 3 Crankshaft
    30
  • 3.1 Assembly overview - crankshaft
    30
  • 3.2 Identification of crankshaft bearings
    31
  • 3.3 Removing and installing sender wheel
    32
  • 3.4 Crankshaft dimensions
    32
  • 4 Pistons and conrods
    33
  • 4.1 Assembly overview - pistons and conrods
    33
  • 4.2 Bearing shells - installation position
    34
  • 4.3 Separating new conrod
    34
  • 4.4 Checking pistons and cylinder bores
    35
  • 4.5 Piston and cylinder dimensions
    36
  • Cylinder head, valve gear
    37
  • 1 Cylinder head
    37
  • 1.1 Assembly overview - cylinder head
    37
  • 1.2 Checking cylinder head for distortion
    38
  • 1.3 Removing and installing cylinder head
    39
  • 1.4 Checking compression
    44
  • 2 Toothed belt drive
    47
  • 2.1 Assembly overview - toothed belt drive
    47
  • 2.2 Removing and installing toothed belt guard
    48
  • 2.3 Removing and installing toothed belt
    49
  • 2.4 Checking semi-automatic toothed belt tensioner
    54
  • 3 Valve gear
    55
  • 3.1 Assembly overview - valve gear
    55
  • 3.2 Removing and installing camshaft oil seal
    57
  • 3.3 Removing and installing camshaft
    59
  • 3.4 Measuring axial play of camshaft
    64
  • 3.5 Removing and installing valve stem seals
    64
  • 3.6 Checking hydraulic compensation elements
    66
  • 4 Inlet and exhaust valves
    67
  • 4.1 Reworking valve seats
    67
  • 4.2 Checking valve guides
    68
  • 4.3 Valve dimensions
    69
  • Lubrication
    70
  • 1 Sump, oil pump
    70
  • 1.1 Assembly overview - sump/oil pump
    70
  • 1.2 Removing and installing sump
    72
  • 1.3 Removing and installing oil pump
    74
  • 1.4 Engine oil:
    75
  • 2 Oil filter, oil pressure switch
    76
  • 2.1 Assembly overview - oil filter/oil pressure switch
    76
  • 2.2 Checking oil pressure and oil pressure switch
    77
  • 2.3 Measuring oil consumption
    78
  • Cooling
    79
  • 1 Cooling system/coolant
    79
  • 1.1 Coolant hose schematic diagram
    79
  • 1.2 Draining and adding coolant
    80
  • 1.3 Checking cooling system for leaks
    87
  • 2 Coolant pump, regulation of cooling system
    89
  • 2.1 Assembly overview - coolant pump, thermostat
    89
  • 2.2 Removing and installing coolant pump
    90
  • 2.3 Removing and installing thermostat
    92
  • 3 Radiator, radiator fan
    94
  • 3.1 Assembly overview - radiator/radiator fan
    94
  • 3.2 Removing and installing radiator
    96
  • 3.3 Removing and installing radiator fan V7 and radiator fan 2 V177
    97
  • Fuel supply system
    99
  • 1 Fuel
    99
  • 1.1 Assembly overview - fuel tank
    99
  • 1.2 Removing and installing fuel tank
    100
  • 2 Fuel delivery unit, fuel gauge sender
    103
  • 2.1 Removing and installing fuel delivery unit
    103
  • 2.2 Installation position of fuel delivery unit
    105
  • 2.3 Removing and installing fuel gauge sender G
    105
  • 3 Fuel filter
    106
  • 3.1 Assembly overview - fuel filter
    106
  • 3.2 Removing and installing fuel filter
    107
  • 4 LPG system
    108
  • 4.1 Assembly overview - evaporator with add-on parts
    108
  • 4.2 Emptying fuel tank
    109
  • 4.3 Emptying the gas line
    113
  • 4.4 Removing and installing evaporator
    113
  • 4.5 Removing and installing fuel tank (LPG)
    115
  • 4.6 Components on fuel tank
    117
  • 4.7 Removing and installing gas injector
    124
  • 4.8 Removing and installing gas rail temperature and pressure sensor GX21
    125
  • 4.9 Checking SERTO adapter leads for leaks
    125
  • 5 Accelerator pedal
    129
  • 5.1 Function
    129
  • 5.2 Assembly overview - accelerator mechanism
    129
  • 5.3 Removing and installing accelerator pedal module
    130
  • 6 Activated charcoal filter system
    132
  • 6.1 Function
    132
  • 6.2 Checking fuel tank breather
    132
  • 7 Fuel pump
    134
  • 7.1 Checking fuel pump
    134
  • Mixture preparation - injection
    142
  • 1 Injection system
    142
  • 1.1 Technical data
    142
  • 1.2 Bleeding fuel system
    142
  • 2 Injectors
    145
  • 2.1 Assembly overview - fuel rail with injectors
    145
  • 2.2 Removing and installing injectors
    145
  • 2.3 Checking injectors for leaks and quantity injected
    146
  • 3 Intake manifold
    151
  • 3.1 Assembly overview - intake manifold
    151
  • 3.2 Removing and installing lower part of intake manifold
    152
  • 3.3 Removing and installing intake manifold
    154
  • 3.4 Checking intake manifold change-over
    159
  • 4 Air filter
    161
  • 4.1 Assembly overview - air filter housing
    161
  • 5 Senders and sensors
    162
  • 5.1 Checking fuel pressure regulator and holding pressure
    162
  • 6 Engine control unit
    165
  • 6.1 Removing and installing engine control unit J623 / J659
    165
  • Exhaust system
    166
  • 1 Exhaust pipes and silencers
    166
  • 1.1 Assembly overview - silencers
    166
  • 1.2 Separating exhaust pipes from silencers
    166
  • 1.3 Installation position of clamps
    168
  • 1.4 Checking exhaust system for leaks
    168
  • 2 Emission control
    169
  • 2.1 Assembly overview - emission control
    169
  • 2.2 Removing and installing catalytic converter
    170
  • 3 Exhaust gas recirculation
    172
  • 3.1 Assembly overview - exhaust gas recirculation
    172
  • 4 Secondary air system
    174
  • 4.1 Function
    174
  • 4.2 Assembly overview - secondary air system
    174
  • 4.3 Checking combination valve
    175
  • 5 Exhaust manifold
    177
  • 5.1 Removing and installing exhaust manifold
    177
  • Ignition system
    179
  • 1 Ignition system
    179
  • 1.1 Assembly overview - ignition system
    179
  • 1.2 Test data, spark plugs
    180
Manufacturer's designation 4-cylinder injection engine (1.6 l engine, BiFuel)
Manufacturer Volkswagen
Suitable for Caddy KA / Caddy Maxi (2011)
Suitable car types 2C
Engine code CHGA
Category Reparaturanleitung

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