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Volkswagen Caddy 2004 – 2011 Workshop Manual – 4-Cylinder Diesel Engine 1.9L Engine

Volkswagen

Workshop-Manual Caddy 2004. 4-Cylinder Diesel Engine 1.9L Engine. Engine ID BJB BLS BSU. Edition 09.2014.

Repair Group
00 – Technical data
10- Removing and installing engine
13- Crankshaft group
15- Cylinder head, valve gear
17- Lubrication
19- Cooling
21 -Turbocharging/supercharging
23 – Mixture preparation – injection
26 – Exhaust system
28 – Glow plug system

CONTENTS

  • 00 – Technical data
  • 1 Identification
  • 1.1 Engine number engine data
  • 2 Safety instructions
  • 2.1 Safety precautions when working on cooling system
  • 2.2 Safety precautions when working on fuel supply system
  • 2.3 Safety precautions when working on charge air system
  • 2.4 Safety precautions when working on injection system
  • 2.5 Safety precautions during road tests in which testing and measuring equipment is used
  • 3 Repair instructions
  • 3.1 Rules for cleanliness when working on fuel supply system/injection system
  • 3.2 Rules for cleanliness when working on charge air system
  • 3.3 General notes on the lubrication system
  • 10- Removing and installing engine
  • 1 Removing and installing engine
  • 1.1 Removing engine
  • 1.2 Removing engine – vehicles with four-wheel drive
  • 1.3 SecuringengineonengineandgearboxsupportVAS6095
  • 1.4 Installing engine
  • 1.5 Installing engine – vehicles with four-wheel drive
  • 2 Assembly mountings .
  • 2.1 Assembly overview – assembly mountings
  • 13- Crankshaft group
  • 1 Cylinder block (pulley end)
  • 1.1 Assembly overview-cylinderblock
  • 1.2 Assembly overview – poly V-belt drive with vane pump
  • 1.3 Assembly overview – poly V-belt drive with vane pump
  • 1.4 RemovingandinstallingpolyV-belt
  • 2 Cylinder block, gearbox end
  • 2.1 Assembly overview-cylinderblock.gearboxend
  • 2.2 Removing and installing dual-mass flywheel
  • 2.3 Removing and installing sealing flange on gearbox side
  • 3 Crankshaft
  • 3.1 Assemblyoverview-crankshaft
  • 3.2 Renewing needle bearing in crankshaft
  • 3.3 Crankshaft dimensions
  • 4 Pistons and conrods
  • 4.1 Assembly overview-pistonsandconrods
  • 4.2 Checking piston and cylinder bore
  • 4.3 Separating new conrod
  • 4.4 Measuring piston projection at TDC
  • 4.5 Cylinder head gasket identification
  • 4.6 Piston and cylinder dimensions
  • 15-Cylinderhead,valvegear
  • 1 Cylinder head
  • 1.1 Assembly overview-cylinderhead
  • 1.2 Removing and installing cylinder head
  • 1.3 Removing and installing cylinder head cover
  • 1.4 Checking compression
  • 2 Toot hed belt drive
  • 2.1 Assembly overview – toothed belt drive
  • 2.2 Removing and installing toothed belt
  • 2.3 Loosening and securing toothed belt
  • 3 Valve gear
  • 3.1 Assembly overview – valve gear
  • 3.2 Measuring axialplayof camshaft
  • 3.3 Removing and installing camshaft
  • 3.4 Removing and installing camshaft oil seal
  • 3.5 Removing and installing valve stem seals
  • 4 Inlet and exhaust valves
  • 4.1 Checking valve guides
  • 4.2 Valve dimensions
  • 17-Lubrication
  • 1 Sump, oil pump
  • 1.1 Assembly overview-sumpandoilpump
  • 1.2 Removing and installing sump
  • 1.3 Engine oil
  • 2.1 Assembly overview – oil filter housing, oil pressure switch
  • 2.2 Checking oil pressure and oil pressure switch
  • 3 Oil circuit f
  • 3.1 Assembly overview-oilsupplyline
  • 3.2 Removing and installing oil supply line
  • 19-Cooling
  • 1 Cooling system, coolant
  • 1.1 Coolant hose schematic diagram
    1.2 Draining and filling coolant
  • 1.3 Checking cooling system for leaks
  • 1.4 Checking engine oil cooler for leaks
  • 2 Coolant pump, regulation of cooling system
  • 2.1 Assembly overview – coolant pump, thermostat
  • 2.2 Removing and installing coolant pump
  • 2.3 Removing and installing thermostat
  • 3 Coolant pipes JT
  • 3.1 Removing and installing rear coolant pipe for additional heater
  • 4 Radiator, radiator fan
  • 4.1 Assembly overview – radiator/radiator fan
  • 4.2 Removing and installing radiator
  • 4.3 Removing and installing fan support with fans
  • 21 -Turbocharging/supercharging
  • 1 Turbocharger
  • 1.1 Assembly overview-turbocharger.enginecodeBJB
  • 1.2 Assembly overview-turbocharger,enginecodesBLS,BSU
  • 1.3 Changing and adjusting vacuum unit on turbocharger, only vehicles with engine codes BLS and BSU as of model year2008
  • 1.4 Removing and installing turbocharger
  • 2 Change air system
  • 2.1 Assembly overview-chargeairsystem.enginecodeBJB
  • 2.2 Assembly overview – charge air system, engine codes BLS,BSU
  • 2.3 Fitting the charge-airsystemhoseconnections
  • 2.4 Checking charge air system for leaks
  • 23 – Mixture preparation – injection
  • 1 Injectors
  • 1.1 Assembly overview-unitinjector
  • 1.2 Removing and installing-ringsforunitinjector
  • 1.3 Removing and installing unit injector
  • 1.4 Removing and installing prewiring for unit injectors
  • 2 Vacuum system
  • 2.1 Connection overview
  • 2.2 Schematic diagram – vacuum system, engine code BJB
  • 2.3 Schematic diagram – vacuum system, engine codes BLS, BSU
  • 3 Air filter
  • 3.1 Assembly overview – air filter
  • 4 Intake manifold
  • 4.1 Assembly overview-intakemanifold.enginecodeBJB
  • 4.2 Assembly overview-intakemanifold,enginecodesBLS,BSU
  • 4.3 Cleaning intake manifold flap connection, engine codes BLS, BSU
  • 5 Engine control unit
  • 5.1 Removing and installing engine control unit
  • 6 High-pressure pump
  • 6.1 Removing and installing fuel pump
  • 6.2 Checking delivery pressure and tandem pump for leaks – engine codes BJB, BLS, BSU
  • 26 – Exhaust system
  • 1 Exhaust pipes, silencers
  • 1.1 Separating exhaust pipes silencers
  • 1.2 Aligning exhaust system free of stress
  • 2 Emission control
  • 2.1 Assembly overview – emission control with catalytic converter
  • 2.2 Assembly overview – emission control with diesel particulate filter, engine codes BLS, BSU
  • 2.3 Removing and installing particulate filter
  • 2.4 Removing and installing particulate filter – vehicles with four-wheel drive
  • 3 Exhaust gas temperature regulation
  • 3.1 Assembly overview-exhaustgastemperatureregulation
  • 4 Exhaust gas recirculation system
  • 4.1 Assembly overview – exhaust gas recirculation system, engine code BJB
  • 4.2 Assembly overview – exhaust gas recirculation system, engine codes BLS, BSU
  • 4.3 Removing and installing exhaust gas recirculation cooler, engine codes BLS, BSU
  • 4.4 Checking mechanical exhaust gas recirculation valve, engine code BJB
  • 28 – Glow plug system
  • 1 Glow plug system
  • 1.1 Removing, installing and checking glow plugs
  • 1.2 Removing, installing and checking ceramic glow pin plugs
  • 1.3 Removing and installing engine speed sender G28

Language: English
Format: PDF
Pages: 221

Volkswagen Caddy 2004 – 2011 Workshop Manual – 4-Cylinder Diesel Engine 1.9L Engine