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4 Cylinder Carburettor Engine Mechanics (1.6L), 2004▸

For Caddy Base

Original Volkswagen repair manual


8,22 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

2.790 KB

82 Sites

Detailed technical data

Immediately readable

This repair manual contains: Self diagnosis, Removing and installing engine, Engine, Sealing flange and pressure plate, Crankshaft, Pistons and conrods, Cylinder head, Lubrication system and Exploded view of exhaust system. Show more
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Repair manual Caddy Base 4 Cylinder Carburettor Engine Mechanics , 2004▸ PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Technical data
    1
  • 1.1 Engine number
    1
  • 1.2 Engine data
    1
  • Self-diagnosis
    2
  • 1 Self diagnosis
    2
  • Engine assembly
    3
  • 1 Removing and installing engine
    3
  • 1.1 Work sequence
    3
  • 1.2 Tightening torques
    6
  • Crankshaft group
    7
  • 1 Engine
    7
  • 1.1 Exploded view of engine
    7
  • 1.2 Removing and installing alternator V-belt
    11
  • 1.3 Adjusting alternator V-belt tension
    11
  • 2 Sealing flange and pressure plate
    13
  • 2.1 Exploded view of sealing flange and pressure plate
    13
  • 2.2 Removing and installing crankshaft oil seal (pulley end)
    14
  • 3 Crankshaft
    16
  • 3.1 Exploded view of crankshaft assembly
    16
  • 3.2 Crankshaft dimensions
    17
  • 4 Pistons and conrods
    18
  • 4.1 Exploded view of piston and conrod
    18
  • 4.2 Checking pistons
    19
  • Cylinder head, Valve gear
    21
  • 1 Cylinder head
    21
  • 1.1 Exploded view of cylinder head
    21
  • 1.2 Removing and installing toothed belt
    22
  • 1.3 Checking and adjusting valve timing
    23
  • 1.4 Removing and installing cylinder head
    25
  • 1.5 Checking cylinder head for distortion
    27
  • 1.6 Checking compression
    27
  • 2 Servicing valve gear
    28
  • 2.1 Exploded view of valve gear
    28
  • 2.2 Checking components of valve gear
    29
  • 2.3 Reworking valve seats
    31
  • 2.4 Removing and installing camshaft oil seal
    33
  • 2.5 Removing and installing camshaft
    34
  • 2.6 Checking hydraulic lifters
    36
  • 2.7 Checking valve guides
    37
  • 2.8 Renewing valve guides
    37
  • 2.9 Renewing valve stem seals (with cylinder head fitted)
    38
  • Lubrication
    41
  • 1 Lubrication system
    41
  • 1.1 Exploded view of lubrication system
    41
  • 1.2 Specifications and capacities
    42
  • 1.3 Checking oil pump backlash
    42
  • 1.4 Checking oil pump axial clearance
    43
  • 1.5 Markings on oil dipstick
    43
  • 1.6 Checking oil pressure and oil pressure switch
    43
  • Cooling system
    46
  • 1 Removing and installing parts of cooling system
    46
  • 1.1 Exploded view of cooling system - body side
    46
  • 1.2 Exploded view of cooling system - engine side
    48
  • 1.3 Exploded view of coolant pump
    49
  • 1.4 Draining and filling cooling system
    50
  • 1.5 Removing and installing coolant pump
    52
  • 1.6 Removing and installing radiator and radiator fan
    53
  • Fuel supply system
    55
  • 1 Removing and installing parts of fuel supply system
    55
  • 1.1 Exploded view of fuel system
    55
  • 1.2 Safety precautions when working on the fuel supply system
    58
  • 1.3 Rules for cleanliness
    58
  • 1.4 Removing and installing fuel gauge sender
    58
  • 1.5 Removing and installing fuel tank
    59
  • 1.6 Gravity valve
    59
  • 1.7 Check valve
    60
  • 1.8 Adjusting throttle cable
    60
  • Mixture preparation, Carburettor
    61
  • 1 Air cleaner
    61
  • 2 Servicing Keihin carburettor
    62
  • 2.1 Exploded view of carburettor - top part
    62
  • 2.2 Exploded view of carburettor - bottom part
    63
  • 2.3 Carburettor technical information
    64
  • 2.4 Arrangement of jets in carburettor
    65
  • 2.5 Checking and adjusting idling speed and CO content
    65
  • 2.6 Checking and adjusting cold idle speed
    65
  • 2.7 Checking and adjusting choke valve gap
    66
  • 2.8 Checking and adjusting quantity injected by accelerator pump
    66
  • 2.9 Basic setting of throttle valve stage II
    67
  • 2.10 Checking and adjusting float level
    68
  • 2.11 Adjusting choke cable
    68
  • Exhaust system
    69
  • 1 Exploded view of exhaust system
    69
  • Ignition system
    71
  • 1 Motronic injection and ignition system
    71
  • 1.1 Exploded view of ignition system
    71
  • 1.2 Safety precautions
    72
  • 1.3 Test data, spark plug
    72
  • 1.4 Removing and installing distributor
    72
  • 1.5 Checking ignition timing
    73
  • 1.6 Checking transistorized control ignition module (T.C.I Unit)
    74
  • 1.7 Checking Hall sender
    75
  • 1.8 Checking ignition transformer
    77
Manufacturer's designation 4 Cylinder Carburettor Engine Mechanics (1.6L), 2004▸
Manufacturer Volkswagen
Suitable for Caddy Base (1999 - 2006)
Suitable car types 170
Engine code BSD
Category Reparaturanleitung

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