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  • Examplepage for repair manual 4-cylinder injection engine (1.6 l roller rocker finger)
  • Examplepage for repair manual 2 4-cylinder injection engine (1.6 l roller rocker finger)
  • Examplepage for repair manual 3 4-cylinder injection engine (1.6 l roller rocker finger)

4-cylinder injection engine (1.6 l roller rocker finger)

For Caddy / Caddy KA / Caddy Maxi

Original Volkswagen repair manual


14,00 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

4.105 KB

164 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, Oil filter, oil pressure switch, Cooling system/coolant, Radiator, radiator fan, Injectors, Intake manifold and Exhaust gas cleaning. Show more
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Repair manual Caddy / 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 regulations for working on fuel supply
    3
  • 2.3 Safety precautions when working on ignition system
    4
  • 2.5 Safety precautions when working on injection system
    4
  • 3 Technical data
    6
  • 3.1 Technical data - injection system
    6
  • 4 Repair instructions
    7
  • 4.1 Rules for cleanliness when working on fuel supply system/injection system
    7
  • 4.2 General notes on ignition system
    7
  • 4.3 General notes on injection
    7
  • 4.4 Foreign objects in engine
    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
    13
  • 1.3 Installing engine
    14
  • 2 Assembly mountings
    16
  • 2.1 Overview - assembly mountings
    16
  • Crankshaft group
    18
  • 1 Cylinder block (pulley end)
    18
  • 1.1 Assembly overview - poly V-belt drive
    18
  • 1.2 Assembly overview - cylinder block
    22
  • 1.3 Removing and installing poly-V belt
    23
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    25
  • 1.5 Removing and installing sealing flange on pulley end
    27
  • 2 Cylinder block, gearbox end
    31
  • 2.1 Assembly overview - cylinder block, gearbox end
    31
  • 2.2 Removing and installing sealing flange on gearbox side
    32
  • 3 Crankshaft
    34
  • 3.1 Assembly overview - crankshaft
    34
  • 3.2 Allocation of main bearing shells
    35
  • 3.3 Removing and installing sender wheel
    36
  • 3.4 Crankshaft dimensions
    36
  • 4 Pistons and conrods
    37
  • 4.1 Assembly overview - pistons and conrods
    37
  • 4.2 Bearing shells - installation position
    38
  • 4.3 Checking pistons and cylinder bores
    38
  • 4.4 Piston and cylinder dimensions
    40
  • Cylinder head, valve gear
    41
  • 1 Cylinder head
    41
  • 1.1 Assembly overview - cylinder head
    41
  • 1.2 Removing and installing cylinder head
    43
  • 1.3 Checking compression
    48
  • 2 Toothed belt drive
    51
  • 2.1 Assembly overview - toothed belt drive
    51
  • 2.2 Removing and installing toothed belt
    53
  • 2.3 Checking semi-automatic toothed belt tensioner
    59
  • 2.4 Removing and installing toothed belt guard
    59
  • 3 Valve gear
    60
  • 3.1 Assembly overview - valve gear
    60
  • 3.2 Removing and installing camshaft oil seal
    62
  • 3.3 Removing and installing camshaft
    64
  • 3.4 Measuring axial play of camshaft
    69
  • 3.5 Removing and installing valve stem seals
    69
  • 3.6 Checking hydraulic compensation elements
    71
  • 4 Inlet and exhaust valves
    73
  • 4.1 Reworking valve seats
    73
  • 4.2 Checking valve guides
    74
  • 4.3 Valve dimensions
    75
  • Lubrication
    76
  • 1 Sump, oil pump
    76
  • 1.1 Assembly overview - sump/oil pump
    76
  • 1.2 Removing and installing oil sump
    79
  • 1.3 Removing and installing oil pump
    81
  • 1.4 Engine oil:
    81
  • 2 Oil filter, oil pressure switch
    83
  • 2.1 Assembly overview - oil filter/oil pressure switch
    83
  • 2.2 Checking oil pressure and oil pressure switch
    85
  • 2.3 Measuring oil consumption
    86
  • Cooling
    88
  • 1 Cooling system/coolant
    88
  • 1.1 Connection diagram - coolant hoses
    88
  • 1.2 Draining and adding coolant
    89
  • 1.3 Checking cooling system for leaks
    96
  • 2 Coolant pump, regulation of cooling system
    98
  • 2.1 Assembly overview - coolant pump, thermostat
    98
  • 2.2 Removing and installing coolant pump
    99
  • 2.3 Removing and installing thermostat
    101
  • 3 Radiator, radiator fan
    103
  • 3.1 Assembly overview - radiator/radiator fan
    103
  • 3.2 Removing and installing radiator
    104
  • 3.3 Removing and installing radiator fan V7 and radiator fan 2 V177
    106
  • Mixture preparation - injection
    108
  • 1 Injection system
    108
  • 1.1 Bleeding fuel system
    108
  • 2 Injectors
    111
  • 2.1 Assembly overview - fuel rail with injectors
    111
  • 2.2 Removing and installing injectors
    111
  • 2.3 Checking injectors
    112
  • 3 Senders and sensors
    117
  • 3.1 Checking fuel pressure regulator and holding pressure
    117
  • 3.2 Checking fuel pressure regulator and holding pressure
    119
  • 4 Intake manifold
    122
  • 4.1 Assembly overview - intake manifold
    122
  • 4.2 Assembly overview - intake manifold
    124
  • 4.3 Removing and installing lower part of intake manifold
    125
  • 4.4 Removing and installing lower part of intake manifold
    127
  • 4.5 Removing and installing intake manifold
    129
  • 4.6 Removing and installing intake manifold
    133
  • 4.7 Checking intake manifold change-over
    136
  • 5 Air filter
    138
  • 5.1 Assembly overview - air filter housing
    138
  • 6 Engine (motor) control unit
    139
  • 6.1 Removing and installing engine control unit J623
    139
  • 6.2 Removing and installing anti-theft engine control unit J623
    140
  • Exhaust system
    142
  • 1 Exhaust pipes and silencers
    142
  • 1.1 Assembly overview - silencers
    142
  • 1.2 Separating exhaust pipes from silencers
    142
  • 1.3 Installation position of clamp
    144
  • 1.4 Check exhaust system for leaks
    144
  • 1.5 Aligning exhaust system free of stress
    144
  • 2 Exhaust gas cleaning
    146
  • 2.1 Assembly overview - emission control
    146
  • 2.2 Removing and installing front exhaust pipe with catalytic converter
    147
  • 3 Exhaust gas recirculation
    149
  • 3.1 Assembly overview - exhaust gas recirculation
    149
  • 4 Secondary air system
    151
  • 4.1 Assembly overview - secondary air system
    151
  • 4.2 Assembly overview - secondary air system
    152
  • 4.3 Function of secondary air system
    153
  • 4.4 Checking combination valve
    153
  • 5 Exhaust manifold
    155
  • 5.1 Removing and installing exhaust manifold
    155
  • Ignition system
    157
  • 1 Ignition system
    157
  • 1.1 Assembly overview - ignition system
    157
  • 1.2 Test data, spark plugs
    158
Manufacturer's designation 4-cylinder injection engine (1.6 l roller rocker finger)
Manufacturer Volkswagen
Suitable for Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)
Suitable car types 2K, 2C
Engine code BSE, BSF
Category Reparaturanleitung

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