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  • Examplepage for repair manual 4-cylinder injection engine (natural gas)
  • Examplepage for repair manual 2 4-cylinder injection engine (natural gas)
  • Examplepage for repair manual 3 4-cylinder injection engine (natural gas)

4-cylinder injection engine (natural gas)

For Caddy / Caddy KA / Caddy Maxi

Original Volkswagen repair manual


13,41 €7% VAT incl.

  • Deutsch
  • English

Immediately available for download

Language: English

Digital PDF file

4.352 KB

156 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 Safety information
    1
  • 1.1 Safety precautions when working on vehicles with a gas system
    1
  • 1.2 Safety regulations for working on fuel supply
    3
  • 1.3 Safety measures when working on vehicles with a start/stop system
    3
  • 1.5 Safety precautions when working on exhaust system
    4
  • 2 Identification
    5
  • 2.1 Engine number/engine data
    5
  • 3 Repair instructions
    6
  • 3.1 General information
    6
  • Removing and installing engine
    8
  • 1 Removing and installing engine
    8
  • 1.1 Removing engine
    8
  • 1.2 Securing engine on engine and gearbox support
    12
  • 1.3 Installing engine
    14
  • 2 Assembly mountings
    17
  • 2.1 Assembly overview - assembly mountings
    17
  • Crankshaft group
    18
  • 1 Cylinder block (pulley end)
    18
  • 1.1 Assembly overview - poly V-belt drive
    18
  • 1.2 Assembly overview - cylinder block (pulley end)
    20
  • 1.3 Removing and installing poly-V belt
    21
  • 1.4 Renewing crankshaft oil seal - belt pulley end
    22
  • 1.5 Removing and installing sealing flange on pulley end
    25
  • 2 Cylinder block, gearbox end
    29
  • 2.1 Assembly overview - cylinder block, gearbox end
    29
  • 2.2 Removing and installing sealing flange on gearbox side
    30
  • 3 Crankshaft
    32
  • 3.1 Assembly overview - crankshaft
    32
  • 3.2 Allocation of main bearing shells
    33
  • 3.3 Removing and installing sender wheel
    34
  • 3.4 Crankshaft dimensions
    34
  • 4 Pistons and conrods
    35
  • 4.1 Assembly overview - pistons and conrods
    35
  • 4.2 Checking pistons and cylinder bores
    36
  • Cylinder head, valve gear
    39
  • 1 Cylinder head
    39
  • 1.1 Assembly overview - cylinder head
    39
  • 1.2 Removing and installing cylinder head
    41
  • 1.3 Checking compression
    46
  • 2 Toothed belt drive
    49
  • 2.1 Assembly overview - toothed belt
    49
  • 2.2 Removing and installing toothed belt
    51
  • 3 Valve gear
    57
  • 3.1 Assembly overview - valve gear
    57
  • 3.2 Measuring axial play of camshaft
    59
  • 3.3 Removing and installing camshaft oil seal
    59
  • 3.4 Removing and installing camshaft
    61
  • 3.5 Removing and installing valve stem seals
    64
  • 4 Inlet and exhaust valves
    67
  • 4.1 Reworking valve seats
    67
  • 4.2 Checking valve guides
    69
  • 4.3 Valve dimensions
    70
  • Lubrication
    71
  • 1 Sump, oil pump
    71
  • 1.1 Assembly overview - sump/oil pump
    71
  • 1.2 Removing and installing oil sump
    73
  • 1.3 Removing and installing oil pump
    75
  • 1.4 Engine oil:
    76
  • 2 Oil filter, oil pressure switch
    77
  • 2.1 Assembly overview - oil filter/oil pressure switch
    77
  • 2.2 Checking oil pressure and oil pressure switch
    78
  • Cooling
    80
  • 1 Cooling system/coolant
    80
  • 1.1 Connection diagram - coolant hoses
    80
  • 1.2 Checking cooling system for leaks
    80
  • 1.3 Draining and adding coolant
    82
  • 2 Coolant pump, regulation of cooling system
    91
  • 2.1 Assembly overview - coolant pump, thermostat
    91
  • 2.2 Removing and installing coolant pump
    92
  • 2.3 Removing and installing thermostat
    94
  • 3 Radiator, radiator fan
    96
  • 3.1 Assembly overview - radiator/radiator fan
    96
  • 3.2 Removing and installing radiator
    97
  • 3.3 Removing and installing radiator fan
    98
  • Mixture preparation - injection
    101
  • 1 Injection system
    101
  • 1.1 Filling/bleeding fuel system
    101
  • 2 Injectors
    104
  • 2.1 Assembly overview - fuel rail with injectors
    104
  • 2.2 Removing and installing injectors
    105
  • 2.3 Checking injectors
    106
  • 3 Checking natural gas supply system for leaks
    110
  • 3.1 Distinguishing between pressure sections of natural gas supply system
    110
  • 3.2 Determining pressure of natural gas system
    112
  • 3.3 Determining operating mode of natural gas vehicles
    113
  • 3.4 Activating and deactivating natural gas mode
    113
  • 3.5 Checking gas system for leaks
    114
  • 4 Gas injectors
    119
  • 4.1 Assembly overview - gas rail with gas injectors
    119
  • 5 Gas pressure regulator
    122
  • 5.1 Assembly overview - gas pressure regulator
    122
  • 5.2 Removing and installing gas pressure regulator
    124
  • 6 Air filter
    131
  • 6.1 Assembly overview - air filter housing
    131
  • 7 Intake manifold
    132
  • 7.1 Assembly overview - intake manifold
    132
  • 7.2 Assembly overview - lower part of intake manifold with fuel rail
    133
  • 7.3 Removing and installing intake manifold upper part
    133
  • 8 Engine (motor) control unit
    136
  • 8.1 Removing and installing engine (motor) control unit J623
    136
  • Exhaust system
    139
  • 1 Exhaust pipes and silencers
    139
  • 1.1 Assembly overview - silencers
    139
  • 1.2 Aligning exhaust system free of stress
    140
  • 1.3 Check exhaust system for leaks
    141
  • 1.4 Installation position of clamp
    141
  • 2 Exhaust gas cleaning
    142
  • 2.1 Assembly overview - emission control
    142
  • 2.2 Removing and installing catalytic converter
    145
  • Ignition system
    149
  • 1 Ignition system
    149
  • 1.1 Assembly overview - ignition system
    149
  • 1.2 Test data, spark plugs
    150
Manufacturer's designation 4-cylinder injection engine (natural gas)
Manufacturer Volkswagen
Suitable for Caddy (2004 - 2010) / Caddy KA / Caddy Maxi (2011)
Suitable car types 2K, 2C
Engine code BSX
Category Reparaturanleitung

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