SM 2.c
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Service Department. Technical Information
Service
List of Workshop Manual Repair Groups
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00 - Technical data
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10 - Removing and installing engine
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13 - Crankshaft group es, in part or in w
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15 - Cylinder head, valve gear
17 - Lubrication
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19 - Cooling
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21 - Turbocharging/supercharging
23 - Mixture preparation - injection
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26 - Exhaust system
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28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2019 Volkswagen AG, Wolfsburg D3E802E92D9
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety measures when working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 2
1.4 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Rules for cleanliness when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Rules for cleanliness when working on turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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10 - Removing byV
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1 horis Removing and installing engine . . . n.te.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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Removing engine . . . . . . . . . . . . . . . . .r a. c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
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1.2 Separating engine from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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1.3 Separating engine from dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.4 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.2 Removing and installing engine mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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2.3 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
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2.5 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Engine cover panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1.1 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.3 Assembly overview - poly V-belt drive without air conditioner compressor . . . . . . . . . . . . 51
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1.4 Assembly overview - poly V-belt drive with air conditioning compressor . . . . . . . . . . . . . . 52
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1.5 Assembly overview - ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1.6 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.9 Removing and installing poly V-belt without air conditioner compressor . . . . . . . . . . . . . . 61
1.10 Removing and installing poly V-belt with air conditioner compressor . . . . . . . . . . . . . . . . 61
1.11 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.12 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.1 Assembly overview - flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Contents i
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.5 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.6 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.7 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
1.5 Removing and installing injector seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
1.6 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2 Fully enclosing toothed belt guard agen
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2.1 Assembly overview - bfully y V enclosing toothed belt guardt gu.a. . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Removing and installing
orise upper toothed belt guard (fully enclosing) tee .................. 118
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2.3 Removing and auinstalling
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lower toothed belt guard (fully enclosed) or
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2.4 Removing and installing rear toothed belt guard (fully enclosing) . . . . . . . . . . . . . . . . . . . . 120
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3 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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3.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
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3.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
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4 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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4.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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4.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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4.3 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.4 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
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4.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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4.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.8 Removing and installing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . 159
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5 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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5.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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5.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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5.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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5.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
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1.2 Removing and installing sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 173
1.6 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
ii Contents
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.1 Assembly overview - oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 179
3.2 Removing aand gen Ainstalling
G. Volkswaoil
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AG dohousing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
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3.3 Removing
by Vol and installing oil pressure ot switch
gu F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
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3.4 Checking
rise oil pressure switch . . . . . . . . .n.te. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
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3.5s aut Checking oil pressure . . . . . . . . . . . . . . . . .o.r a.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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4.1 Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
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4.2 Removing and installing oil supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
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1.2 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
1.4 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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2.2 Assembly overview - coolant pump and thermostat, from week 22/2011 . . . . . . . . . . . . . . 207
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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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2.4 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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2.5 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 214
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2.6 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 215
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3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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3.2 Removing and installing cowling together with radiator fan V7 and radiator fan on right of
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radiator V35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
4.2 Removing and installing lower coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
4.3 Removing and installing upper coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.4 Removing and installing left coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.5 Removing and installing right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
1.3 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . 242
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
2.4 Removing and installing charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.5 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
...................................................................... 250
2.6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
1.3 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Contents iii
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.5 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3.1 Overview - fuel return lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3.2 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.3 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
3.4 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
3.5 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
3.6 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
3.7 Replacing O-ring of fuel return lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3.8 Check pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
3.9 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
3.10 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4 High-pressure pump . . . . . . . .a.ge. n. A.G. . .V.ol.ks.w.a.g.en. A. G. d. o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
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4.1 Assembly overview - high-pressure olks pump . . . . . . . . . . n.o.t g.u. . . . . . . . . . . . . . . . . . . . . . . . . 301
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4.2 Removing and installing oris high-pressure pump . . . . . . . . . . . . n.te.e. . . . . . . . . . . . . . . . . . . .
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4.3 th
Pressure testing high-pressure pump . . . . . . . . . . . . . . . . . . . . .or.ac. . . . . . . . . . . . . . . . . . 306
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4.4 Checking high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
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5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
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5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
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5.3 Removing and installing throttle valve module GX3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
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6 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
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6.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
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6.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rrectness of i 321
7.1 Removing and installing Lambda probe G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
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8 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
8.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
8.2 Removing and installing pressure differential sender G505 . . . . . . . . . . . . . . . . . . . . . . . . 324
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8.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 324
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8.4 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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8.5 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
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8.6 Checking fuel pressure sender G 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
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8.7 Checking fuel metering valve N 290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
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9 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
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9.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 334
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9.2 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 335
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1 Exhaust pipes and silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
1.2 Separating exhaust pipes from silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
1.3 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
1.4 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.1 Assembly overview - catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
2.2 Assembly overview - particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 350
3.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 351
iv Contents
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3.3 Removing and installing exhaust gas temperature sender 3 G495 . . . . . . . . . . . . . . . . . . 352
3.4 Removing and installing exhaust gas temperature sender 4 G648 . . . . . . . . . . . . . . . . . . 354
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
4.2 Checking changeover for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . 358
4.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 359
4.4 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.5 Cleaning exhaust gas recirculation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
1.1 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
1.2 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 371
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
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Contents v
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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vi Contents
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine,
olksw
common rail) - Edition 07.2019
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⇒ “1.2 Safety measures when working on fuel supply”,
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⇒ “1.3 Safety precautions when using testers and measuring in‐
struments during a road test”, page 2
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⇒ “1.4 Safety precautions when working on injection system”,
page 3
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1.1 Safety precautions when working on the
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cooling system
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Caution
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all kinds of lines (e.g. for fuel, hydraulics, activated
charcoal system, coolant and refrigerant, brake fluid, vac‐
uum) and electrical cables so that the original line routing
is re-established.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.
1. Safety information 1
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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♦ Cooling system is pressurized when engine is warm.utho If nec‐ eo
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♦ Hose connections are secured with spring-type clips. In case
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♦ When installing, make sure that the coolant hoses are routed
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1.2 Safety measures when working on fuel
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♦ Ensure that there is sufficient clearance to all moving or
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♦ The fuel and the fuel lines in the fuel system can become
very hot (danger of scalding)!
♦ The fuel system is also under pressure! Before opening
the system, wrap a cloth around the connection and care‐
fully loosen to release the pressure!
♦ Wear eye and hand protection when performing any type
of repair work on the fuel system!
When removing and installing fuel gauge sender or fuel pump
(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Place the suction hose of an activated exhaust gas extraction
system close to the assembly opening of the fuel tank to ex‐
tract any fuel vapours that are released. If no exhaust gas
extraction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
in air flow.
♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
1.3 Safety precautions when using testers
and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test instruments and measuring equipment must always be
secured to the rear seat and operated by a second person from
this location.
2 Rep. gr.00 - Technical data
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen
♦ Operating from the front passenger
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1.4 Safety
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jection system
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♦ Do not open any fuel line connections while the engine is run‐
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♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
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♦ Always switch off ignition before cleaning engine.
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♦ The battery should only be disconnected and reconnected
with ignition switched off.
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♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all checks and re‐
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pairs, the fault memory must be read and if necessary cleared.
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1. Safety information 3
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Identification
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Four digit engine
s codes
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The first 3 digits refer to the mechanical configuration of the en‐
an
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gine. They are stamped onto the engine.
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The fourth digit indicates the output of the engine. It depends on
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the engine control unit.
h re
ole,
The four-digit engine code can be found on the type plate, the
spec
urposes, in part or in wh
vehicle data label and on the engine control unit.
t to the co
The engine number (“code letters” and “serial number”) -arrow-
can be found on the joint between engine and gearbox.
rrectne
In addition, there is a sticker on the toothed belt guard with “engine
code” and “serial number”.
ss o
The engine codes can also be found on the vehicle data sticker.
cial p
f inform
The engine number consists of up to 9 characters (alphanumeric).
mer
The first part (maximum 4 characters) makes up the “engine
atio
m
code”, and the second part (6 characters), the “serial number”. If
o
n
c
i
more than 999,999 engines were produced with the same code
or
n thi
e
letters, the first of the six digits is replaced by a letter.
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Codes CAYD CAYE
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Manufactured 08.10 ► 08.10 ►
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cted
Exhaust emissions fulfil EU5 standard EU5 standard
agen
Prote AG.
Displacement 1.6 1.6
Power kW at rpm 75/4400 55/3000 … 4000
Torque Nm at rpm 250/ 225/
1500 … 2500 1500 … 2250
Bore ∅ mm 79.5 79.5
Stroke mm 80.5 80.5
Valves per cylinder 4 4
Compression ratio 16.5 16.5
Fuel: In accordance DIN EN 590 DIN EN 590
with
Firing order 1-3-4-2 1-3-4-2
Catalytic converter YES YES
Exhaust gas recirculation YES YES
Charging YES YES
Charge air cooling YES YES
Particulate filter YES YES
4 Rep. gr.00 - Technical data
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 General information
⇒ “3.1 General notes on injection”, page 5
⇒ “3.2 General notes on the lubrication system”, page 5 . Volkswagen AG
gen AG a does
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⇒ “3.3 General notes on fuel system”, paged b6y Vo gu
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or
3.1 General notes ons injection
au
th eo
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c
s
⇒ page 268
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du
an
itte
♦ If fuel system has been opened, it must be bled before engine
y li
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is started ⇒ page 268 .
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♦ Fuel hoses in engine compartment must be secured only with
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, is n
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spring-type clips which conform to production standard. The
hole
use of crimp-type or screw-type clips is not permissible.
spec
es, in part or in w
♦ The battery must be disconnected only with ignition switched
t to the co
off. If a coded radio is installed, ascertain code before discon‐
necting battery.
rrectness of i
♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
l purpos
♦ Do not use sealants containing silicone. Particles of silicone
drawn into the engine will not be burnt in the engine and dam‐
nform
ercia
age the lambda probe.
m
at
om
i
♦ If, after fault finding, repairs or component tests, the engine
on
c
starts, runs for a short period and then stops, then the fault
in t
or
his
e
may be that the immobilizer is blocking the engine control unit.
at
do
riv
In this case, the control unit must be adapted ⇒ Vehicle diag‐
p
cum
or
nostic tester.
f
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ng
t.
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♦ Certain tests may lead to a fault being detected by the control t. Cop py
unit and stored. Therefore, after completing all the checks and
rig
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repairs, read the event memory and clear it if necessary op Vo
by c lksw
⇒ Maintenance ; Booklet 39 . cted agen
Prote AG.
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
reduces the danger of a fire in a crash as the fuel pump is
switched off via the fuel pump relay.
♦ When driver door is opened, fuel pump is activated for 2 sec‐
onds to generate pressure in fuel system. This improves the
quality of the start behaviour.
3.2 General notes on the lubrication system
Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter!
3. General information 5
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Caution
Finding metal shavings or a large quantity of small metal par‐
ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil spray jets,
♦ Renew engine oil cooler,
♦ Renew oil filter element.
Drain engine oil ⇒ Maintenance ; Booklet 39 ; Engine oil: Drain
or extract; renew oil filter and replenish engine oil .
Engine oil specifications ⇒ Maintenance ; Booklet 39 ; Service
tables
3.3 General notes on fuel system
To prevent the high-pressure fuel pump from running while it is
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe theofollowing:
lksw AG. V agen AG
agen do
♦ If fuel system components Vbetween
olks
w
fuel tank and fuel ehigh-
s no
t gu
pressure pump are removeded by
or renewed, initial fuel filling must ara
nte
is
be carried out. thor eo
au ra
c
♦ If a fuel pump, fuel
ss line (between fuel tank and fuel high-pres‐
ce
e
sure pump) or the fuel filter is removed or renewed, fuel system
nl
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du
bleeding must be carried out before first starting engine.
an
itte
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♦ If the high-pressure fuel pump is removed or renewed, the fuel
ility
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system must be bled before engine is started for the first time.
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, is n
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♦ Initial fuel filling procedure ⇒ page 268 .
hole
spec
• Clean tools and workbench etc. before working on injection
es, in part or in w
t to the co
system.
• Thoroughly clean all connections and adjacent areas before
disconnecting.
rrectness of i
• When removing components, seal all open connections im‐
l purpos
mediately with suitable, clean protective caps.
• Do not remove sealing caps from components until immedi‐
nform
ercia
ately prior to installation. Removed components should be
m
kept in new, sealable plastic bags (use the original new part
at
om
io
packaging if possible).
n
c
in t
or
his
e
• Before installation, check injectors and their surroundings vis‐
at
do
riv
ually; they must be undamaged and free of lint. Ensure that
p
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or
the injector bore is clean. If necessary, clean injector bore.
f
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ng
t.
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• Only cleaning set - VAS 6811- may be used for cleaning the . Cop py
sealing surface of the injector bore.
ht rig
rig ht
py by
co Vo
• For detailed information on how to use the cleaning set as well
by lksw
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Prote
as the order in which its components are applied, refer to the
AG.
⇒ operating manual provided with the cleaning set - VAS
6811- .
• If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
• The following components and seals/O-rings must always be
renewed when the injectors are removed and installed: “cop‐
6 Rep. gr.00 - Technical data
AG. Volkswagen AG d Caddy 2011 ➤
agen
4-cylinder diesel
Volkswengine (1.6 l engine, common
oes
not rail) - Edition 07.2019
y gu
db ara
ise nte
per seal”, “O-ring for injector bore”,tho “O-ring for
r
injector return eo
s au
connection”, “injector return connection clip” ra
c
s
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• The following components and seals/O-rings must always be
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renewed when an injector is renewed: “copper seal”, “O-ring
itte
y li
for injector shaft” and “O-ring for injector return connection”
erm
ab
“injector return clip”
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, is n
• Always fit new copper seals for the injectors. Check all new O-
h re
rings for damage before installing. O-rings must be moist when hole
spec
installed (assembly oil or clean engine oil). Use assembly tool
es, in part or in w
to install the “O-ring for injector return connection”.
t to the co
• Take care not to damage the injectors when removing the old
copper seals.
rrectness of i
• Align high-pressure lines free from tension. First tighten all
l purpos
unions hand-tight and then tighten to torque.
• Never attempt to reshape high-pressure fuel lines.
nform
ercia
• When working on any parts of the high-pressure fuel system,
m
at
tools may only be used for loosening and tightening pipe un‐
om
ion
ions. All other components must always be removed and
c
in t
or
installed by hand without using tools or other equipment.
his
ate
do
riv
• Disassembling individual common rail components is not per‐
p
cum
or
mitted.
f
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t.
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op
• The components should be replaced as complete units if faul‐
C py
t. rig
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ty.
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pyri by
Vo
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by c lksw
• Never attempt to bleed the common rail system by loosening
cted agen
Prote AG.
high-pressure components after starting the engine.
• Do not carry out any installation work on common rail system
whilst engine is running.
• In particular, do not open or release high-pressure lines and
electrical connectors.
• All cable ties that are opened or cut through during removal
must be secured in the same position during installation.
• When the fuel system is open: do not work with compressed
air if this can be avoided. Try not to move the vehicle.
• Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3. General information 7
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 Repair instructions
⇒ “4.1 Rules for cleanliness when working on fuel supply system”,
page 8
⇒ “4.2 Rules for cleanliness when working on injection system”,
page 8
⇒ “4.3 Rules for cleanliness when working on turbocharger”, page
9
⇒ “4.4 Foreign objects in engine”, page 9
4.1 Rules for cleanliness when working on
fuel supply system
When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules”:
♦ Thoroughly clean all connections and adjacent areas before
disconnecting.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only. agen
AG. Volkswagen AG d
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olks ot g
♦ Carefully cover opened componentseor d b seal them if repairs
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ran
cannot be carried out immediately.
ho
ris tee
t or
au ac
♦ Install clean components only.ssDo not remove replacement
parts from packing until immediately before installing. Do not
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un
pt
use parts that have been kept unpackaged (for example in
an
d
itte
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toolboxes).
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ab
pe
ility
♦ If system is open, do not work with compressed air. Do not
ot
wit
move the vehicle.
, is n
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hole
4.2 Rules for cleanliness when working on
spec
es, in part or in w
injection system t to the co
When working on the fuel supply/injection system, pay careful at‐
tention to the following “5 rules”:
rrectness of i
♦ Thoroughly clean all connections and adjacent areas before
l purpos
disconnecting.
♦ Place removed parts on a clean surface and cover them over.
nform
ercia
Use lint-free cloths only.
m
a
com
ti
♦ Carefully cover opened components or seal them if repairs
on in
cannot be carried out immediately.
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te o
thi
s
iva
♦ Install clean components only. Do not remove replacement
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parts from packing until immediately before installing. Do not
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use parts that have been kept unpackaged (for example in
n
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toolboxes). t. Cop py
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♦ If system is open, do not work with compressed air. Do not p by
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move the vehicle.
lksw
cted agen
Prote AG.
8 Rep. gr.00 - Technical data
n AG. Volkswagen AG do
lkswage es n
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byV ua
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d ran
tee Caddy 2011 ➤
o
auth 4-cylinder diesel engine or(1.6
ac l engine, common rail) - Edition 07.2019
ss
ce
4.3 e Rules for cleanliness when working on
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du
an
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turbocharger
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ility
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Caution
h re
hole
spec
If a mechanical fault is found on the turbocharger, e.g. a de‐
es, in part or in w
t to the co
stroyed compressor impeller, just renewing the turbocharger is
not enough. To avoid subsequent damage, the following work
must be carried out:
rrectness of i
♦ Check air filter housing, air filter element and intake hoses
for soiling.
l purpos
♦ Check the whole charge air path and charge air cooler for
foreign objects.
nf
ercia
orm
m
If foreign objects are found in the charge air system, the charg‐
atio
m
ed air routing must be cleaned and the charge air cooler must
o
n in
c
be renewed, if necessary.
or
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When working on the turbocharger, pay careful attention to the
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t.
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following rules for cleanliness:
Co
Cop py
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♦ Thoroughly clean all connections and adjacent areas before
ht
pyri by
Vo
disconnecting.
co lksw
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cted agen
Prote AG.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs
cannot be carried out immediately.
♦ Install clean components only. Do not remove replacement
parts from packing until immediately before installing. Do not
use parts that have been kept unpackaged (for example in
toolboxes).
♦ Transportation and protective packaging and sealing caps
must be removed only immediately before fitting.
♦ When making repairs, remove oil from connection and hose
ends.
♦ When installing, does not use any fluid containing oil, silicone
or grease.
♦ If system is open, do not work with compressed air. Do not
move vehicle unless absolutely necessary.
4.4 Foreign objects in engine
Note
If large quantities of swarf or metal particles (caused, for example,
by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
4. Repair instructions 9
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
10 – Removing and installing engine
1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
en AG. V
olkswagen AG
ag does
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⇒ “1.2 Separating engineVol
by from gearbox”, page 22 d
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ara
ise n
⇒ “1.3 Separatinguthengine
or from dual clutch gearbox”, page 23 tee o
ra
sa c
⇒ “1.4 Securing
s engine on engine and gearbox support”,
ce
e
page 25
nl
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du
an
itte
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⇒ “1.5 Installing engine”, page 26
erm
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ility
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1.1 Removing engine
wit
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hole
spec
Special tools and workshop
es, in part or in w
t to the co
equipment required
rrectness of i
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nf
ercia
orm
m
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om
n in
or c
thi
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
♦ Lifting tackle - 3033-
♦ Hose clamps to 25 mm - 3094-
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
♦ Ladder - VAS 5085- discontinued, use steps - VAS 6292/4-
10 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Workshop hoist - VAS 6100-
♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
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♦ Drip tray for workshop hoist - VAS 6208- s
ce
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un
pt
an
d
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Pliers for spring-type clips - VAS 6362-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
♦ Tensioning straps - T10038-
1. Removing and installing engine 11
AG. Volkswagen AG d
agen oes
olksw not
Caddy 2011 ➤ d byV gu
ara
e
4-cylinder diesel engine
horis (1.6 l engine, common rail) - Edition n07.2019
tee
aut or
ac
ss
♦ Ratchet ring spanner - T10384-
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Transportation lock - T10403-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
Note
♦ Read out radio anti-theft code as the battery earth strap has
to be disconnected during the next work steps.
♦ The engine is removed forwards together with the gearbox.
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed in the same position when the
engine is installed.
WARNING
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
♦ e.g. for fuel, hydraulics, activated charcoal filter system,
coolant and refrigerant, brake fluid, vacuum.
♦ Ensure that there is sufficient clearance to all moving or
hot components.
12 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove air filter housing with air mass meter and connecting
pipe ⇒ page 318 .
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
– Remove battery tray. To do so, remove bolts -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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nl
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du
an
– Detach vacuum line -arrow- on brake servo.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
– Open clip -2- and pull off fuel return hose -1-.
rm
m
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om
n in
or c
thi
te
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f
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ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Open clip and pull off fuel supply line -arrow- from high pres‐
sure pump.
1. Removing and installing engine 13
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -arrows-.
– Disconnect electrical connector -1- for coolant shortage indi‐
cator switch - F66- and push coolant expansion tank to side.
– Unclip coolant hose bracket -1- by pushing to side.
– Loosen bolt -1-.
– Unscrew bolt -2- and nut -3-.
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
(fuel hoses -5- and -6- remain connected).
olkswagen AG
en AG. V
– Collect any escaping fuel. olkswag does
not
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– Remove noise insulation
orise ⇒ General body repairs, exterior; nte
Rep. gr. 66 ; Bodyaut front; Noise insulation .
h eo
ra
ss c
– Drain coolant ⇒ page 194 .
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
Vehicles with air conditioning system
l purpos
– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 87 .
nf
ercia
– Unbolt refrigerant lines -arrow- ⇒ Heater, air conditioning sys‐
orm
tem; Rep. gr. 87 at lock carrier.
m
atio
om
n in
or c
thi
te
sd
iva
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cu
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f
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ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
14 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Continued for all vehicles
olkswagen AG
en AG. V
– Remove lock carrier ⇒ General body repairs, olks exterior; Rep.
wag does
not
gr. 50 ; Body, front; Lock carrier . ed by V gu
ara
ris nte
– Unscrew bolt -arrow- and placeaufiller
tho neck for windscreen eo
ra
washer system reservoir to one
s side.
s c
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le
un
– Remove coolant expansion tank and place on engine.
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Pull off vacuum hoses -1- and -2- for charge air control.
– Disconnect connectors.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
iva
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cum
fo
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t.
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♦ -1- Exhaust gas temperature sender 3 - G495-
Co
Cop py
ht. rig
♦ -2- Exhaust gas temperature sender 1 - G235- rig ht
py by
co Vo
by lksw
♦ -3- lambda probe - G39- cted agen
Prote AG.
– Pull out wiring connector -1- for exhaust gas temperature
sender 4 - G648- from bracket -2- behind battery, release and
separate.
– Guide lines out of brackets on plenum chamber bulkhead and
on turbocharger.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body, front; Plenum chamber bulkhead .
– Remove engine control unit from its bracket ⇒ page 334 .
1. Removing and installing engine 15
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
n AG. Volkswagen AG do
– Release connector for engine wiring harness -arrow- and pull olkswage es n
ot g
off from engine control unit. db
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ran
e
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tho or
au ac
ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Open catch -A- of feed-through in plenum chamber bulkhead
and pull out upper part upwards. Remove engine wiring har‐
rrectness of i
ness from cable guide.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
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cum
for
en
ng
t.
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Cop py
ht. rig
– Unscrew bolt -arrow- (captive bolt). Twist intake hose -A- rig ht
py by
clockwise out of its holder and remove it.
co Vo
by lksw
cted agen
Prote AG.
– Disconnect plug-in connectors for heat exchanger -arrows- on
plenum chamber bulkhead.
16 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew positive cable -arrow- from starter at central electrics
and place cable on engine.
– Detach connectors -1- and-2- from left longitudinal member of
vehicle.
– Remove engine wiring harness from cable guide.
– Unbolt earth cable on gearbox.
– Place engine wiring harness on engine.
Vehicles with dual clutch gearbox
– Remove selector mechanism from gearbox ⇒ Power trans‐
mission; Rep. gr. 34 .
. Volkswagen AG
gen AG d
– Release catch on mechatronicVconnector
olks
wa by pulling -arrow-
oes
not
and pull connector off. ed by gu
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Vehicles with manual gearbox
hole
spec
es, in part or in w
– Remove selector mechanism from gearbox ⇒ Power trans‐
t to the co
mission; Rep. gr. 34 .
– Unscrew bolt -3-.
rrectness of i
l purpos
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tion in
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Prote AG.
1. Removing and installing engine 17
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove bolts -arrows- and lay clutch slave cylinder aside. Do
not open hydraulic system.
– Guide clutch slave cylinder under strut -1-.
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Continued for all vehicles
hole
spec
– Disconnect all connectors between starter, gearbox and body.
es, in part or in w
t to the co
– Disconnect connector -2- from pressure differential sender -
G505- .
rrectness of i
– Unscrew bolts -3- and -4-.
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Prote AG.
– Unclip lines for pressure differential sender - G505- from upper
toothed belt guard together with bracket -1-.
– Lay pressure differential sender - G505- with lines down to
rear.
18 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -1- for pressure differential sender - G505-
bracket.
– Remove pressure differential sender - G505- bracket.
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– Undo bolt -arrow- in upper bracket of particulate filter. Loosen
h re
hole
securing bolt on cylinder head one turn.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
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thi
– Detach connector from oil level and oil temperature sender -
s
iva
do
G266- .
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– Remove right drive shaft cover.
– Remove drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .
1. Removing and installing engine 19
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fasten the two drive shafts to the suspension strut with the
tensioning straps - T10038- .
– First unscrew bolt -1-.
– Then, undo bolts -2- and -3-.
Vehicles with auxiliary heater
– Clamp off coolant hoses -1- and -2- with hose clips up to
25 mm - 3094- and pull coolant hoses from auxiliary heater. AG. Volkswagen AG d
agen oes
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Continued for all vehicles
spec
es, in part or in w
t to the co
– Remove securing clamp -1- between particulate filter and tur‐
bocharger.
rrectness of i
l purpos
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Prote AG.
20 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Loosen securing nuts above particulate filter bracket -1- using
ring ratchet spanner - T10384- .
– Unscrew securing nuts -2- for particulate filter bracket on
crankcase.
– Push particulate filter aside and secure on plenum chamber
bulkhead by suitable means.
Note
Check that all hose and line connections between engine, gear‐
box and body have been detached.
– Use lifting tackle - 3033- and workshop hoist - VAS 6100- to
support »engine/gearbox assembly« in installation position.
Vibration damper end:
• Item 2. AG. Volkswagen AG d
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Flywheel end: ised b ara
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– Remove securing bolts -arrows- of assembly mounting on en‐
hole
gine.
spec
es, in part or in w
t to the co
rrectness of i
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– Remove securing bolts -arrows- of assembly mounting on
t
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Carefully guide »engine/gearbox assembly« when removing to Prote
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agen
avoid damage to body.
– Slightly lift »engine/gearbox assembly« and remove forwards.
1. Removing and installing engine 21
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Check needle roller bearing -arrow- in crankshaft. If it is dam‐
aged or has turned blue, it must be renewed ⇒ page 77 .
– If it is not damaged, lightly lubricate with commercially availa‐
ble grease.
Secure engine to engine and gearbox support - VAS 6095A- to
carry out repairs ⇒ page 25 .
1.2 Separating engine from gearbox
Special tools and workshop equipment required
♦ Hook - 10 - 222 A /2-
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♦ Workshop hoist - VAS 6100-
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♦ Lifting tackle - T40013-
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22 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .
– Attach lifting tackle - T40013- to gearbox and close lock.
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /
2- to lifting tackle.
– Unscrew bolts -1- and -2- and remove starter from gearbox.
AG. Volkswagen AG d
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– Unscrew bolts -1, 3, 4- from gearbox/engine connection.
un
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– Pull gearbox off engine.
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Disregard -items 2, 5, A-
t to the co
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1.3 Separating engine from dual clutch
inform
mer
gearbox
atio
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Special tools and workshop equipment required
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or
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Prote AG.
1. Removing and installing engine 23
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Lifting eye bolt - 3368-
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♦ Shackle - 10 - 222 A /12-
erm
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spec
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mer
atio
♦ Workshop hoist - VAS 6100-
om
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Sequence of operations
• Engine/gearbox assembly removed, eye bolt - 3368- has been
screwed into gearbox.
– Attach workshop hoist - VAS 6100- with shackle - 10 - 222 A /
12- to eye-head bolt - 3368- .
24 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull off both breather caps -arrows- and close using suitable
plugs to achieve an oil-tight seal.
– Unscrew bolts securing gearbox to engine.
– Pull gearbox off engine.
1.4 Securing engine on engine and gearbox
support
Special tools and workshop equipment required
♦ Lifting tackle - 3033-
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♦ Engine and gearbox support - VAS 6095A-
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♦ Workshop hoist - VAS 6100-
nform
mercia
a
com
tion in
r
te o
thi
s
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Cop py
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Prote AG.
1. Removing and installing engine 25
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
• Gearbox detached from engine.
– Attach lifting tackle - 3033- as follows and lift slightly with
workshop hoist - VAS 6100- .
Flywheel end: position 4
Vibration damper end: position 8.
– Secure engine on engine and gearbox support - VAS 6095A- .
AG. Volkswagen AG d
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1.5 Installing engine ise nte
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Install in reverse order of removal, observing the following: s
ce
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Note
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When renewing the engine/cylinder head, note that the plug in the wit
is n
h re
cylinder head must be renewed. This plug seals the oil passage
ole,
spec
against the exterior.
urposes, in part or in wh
t to the co
WARNING
rrectne
It is essential to refer to TPI 2030906/1 before installing engine.
Not adhering to these instructions can lead to damage to the
ss
cylinder head or cylinder head cover.
o
cial p
f inform
mer
atio
om
n
c
Note
i
or
n thi
te
sd
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♦ Renew bolts tightened through an additional specified angle.
i
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pr
cum
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fo
en
ng
♦ Renew self-locking nuts and bolts, and seals, O-rings and
t.
yi Co
gaskets. Cop py
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♦ Hose unions and air intake pipes and hoses must be free of py by
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oil and grease before installation.
by lksw
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Prote AG.
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic parts catalogue (ETKA) .
♦ Attach cable ties in all the same places when installing.
26 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
– Check that intermediate plate is hooked into sealing flange
and pushed onto dowel sleeves -arrows-.
Fastening, dual clutch gearbox to engine
AG. Volkswagen AG d
agen oes
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
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t.
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Cop py
t. rig
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Prote AG.
1. Removing and installing engine 27
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
M12 - 80 Nm
❑ If 18 mm insert -
T10179- is used: 65 Nm.
M10 - 40 Nm
- Arrows point towards dowel
sleeves
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t to the co
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tion in
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te o
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s
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Cop py
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Prote AG.
28 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Fastening manual gearbox to engine
Item Bolt Nm
1 M12 x 55 80
21) M12 x 150 80
3 M10 x 50 40
4 M12 x 60 80
52) M6 x 8 10
A Dowel sleeves for centring
• 1) Also secures starter
• 2) Cover plate for flywheel
Vehicles with manual gearbox
– If clutch release bearing is worn, renew it ⇒ Rep. gr. 30 .
– Lightly grease gearbox input shaft splines with grease for
clutch plate splines ⇒ Electronic parts catalogue (ETKA) .
– Check centring of clutch plate.
– Install clutch slave cylinder a⇒ nPower
AG. Volktransmission;
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does Rep. gr.
w ge
30 . y Volks not
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– Install gearboxhselector
ris mechanism and adjust it, if necessary
nte
t o eo
⇒ Power transmission;
sa
u Rep. gr. 34 . ra
c s
– Install cables with cable support bracket ⇒ Power transmis‐
ce
e
nl
pt
du
sion; Rep. gr. 34 .
an
itte
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erm
ab
– Install hydraulic line for hydraulic clutch ⇒ Power transmis‐
ility
ot p
sion; Rep. gr. 30 .
wit
, is n
h re
– Install gearbox selector mechanism and adjust it, if necessary
hole
⇒ Power transmission; Rep. gr. 34 .
spec
es, in part or in w
t to the co
Vehicles with dual clutch gearbox
Repairing clutch ⇒ Power transmission; Rep. gr. 30 .
rrectness of i
– Install gearbox selector lever cable and adjust it, if necessary
l purpos
⇒ Power transmission; Rep. gr. 34 .
– Check needle roller bearing -arrow- in crankshaft. If it is dam‐
nf
ercia
aged or has turned blue, it must be renewed ⇒ page 77 .
orm
m
atio
– If it is not damaged, lightly lubricate with commercially availa‐
om
ble grease.
n in
or c
thi
te
sd
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f
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ng
t.
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Cop py
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co lksw
by
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Prote AG.
1. Removing and installing engine 29
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Continued for all vehicles:
– Guide engine/gearbox assembly into body.
– When installing »engine/gearbox assembly«, ensure sufficient
clearance to subframe.
Note
♦ Screw in bolts -2- and -3- first.
♦ Then screw in bolt -1-.
– Adjusting assembly mountings ⇒ page 42 .
Note
♦ After working on particulate filter, ensure it is installed free of
stress.
♦ Renew self-locking nuts, seals, gaskets and securing clamps.
Caution
Avoid damaging flexible joint behind particulate filter. When
removing and installing:
♦ Do not allow the flexible joint to kink by more than 10°.
♦ Install flexible joint so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
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– Install particulate filter ⇒ page 350 . yV
olks ot g
ua
b
ed ran
– Bolt drive shafts to gearbox ⇒ Running horis gear, axles, steering; tee
Rep. gr. 40 ; Drive shaft; Removing au and installing drive shafts .
t or
ac
ss
ce
le
un
pt
– Install heat shield for right drive shaft -1- ⇒ Power transmis‐
an
d
itte
sion; Rep. gr. 34 ; Removing and installing gearbox .
y li
rm
ab
pe
ility
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
ot
moving and installing starter .
wit
, is n
h re
hole
– Installing radiator ⇒ page 219 .
spec
es, in part or in w
– Connect coolant hoses with plug-in connector to heat ex‐
t to the co
changer for heater.
– Install pressure differential sender - G505- .
rrectness of i
– Install washer fluid reservoir filler pipe with filler neck.
l purpos
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
nform
ercia
– Install battery mounting and battery ⇒ Electrical system; Rep.
m
gr. 27 ; Battery; Removing and installing battery .
com
tion in
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te o
thi
s
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cum
fo
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Cop py
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by
cted agen
Prote AG.
30 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– When fitting intake connecting pipe to turbocharger, ensure
that intake connecting pipe is correctly seated
agen on stud of tur‐AG does
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bocharger. -arrow-. olksw not
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– Install air filter housing ⇒ pagetho319
ris . e or
au ac
– Check oil level ⇒ page 173ss.
ce
e
nl
pt
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
du
an
itte
50 ; Body, front; Lock carrier .
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ility
– Charge air conditioner ⇒ Heating, air conditioning; Rep. gr.
ot p
wit
87 .
, is n
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hole
– Observe notes after connecting battery ⇒ Electrical system;
spec
Rep. gr. 27 ; Disconnecting and reconnecting battery .
es, in part or in w
t to the co
Caution
rrectness of i
Danger of destroying control units through overvoltage.
l purpos
♦ Never use battery charging equipment for boost starting.
nf
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orm
– Add coolant ⇒ page 194 .
m
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– Filling fuel system ⇒ page 268 .
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sd
– Read event memories of all control units.
iva
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– Clear all entries in event memory which may have occurred
o
m
f
en
ng
during installation ⇒ Vehicle diagnostic tester.
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Cop py
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– Check headlight adjustment and correct if necessary ⇒ Main‐ yri
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tenance ; Booklet 39 . cop Vo
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– Install noise insulation ⇒ General body repairs, exterior; Rep.
AG.
gr. 66 ; Body - front; Noise insulation .
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
♦ ⇒ “2.2 Assembly overview - particulate filter”, page 344
♦ ⇒ “2.1 Assembly overview - catalytic converter”, page 342
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
♦ Drive shafts; Assembly overview - drive shafts ⇒ Rep. gr. 40 ;
Assembly overview - drive shafts .
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 66 ; Assembly overview - noise insulation .
1. Removing and installing engine 31
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 32
⇒ “2.2 Removing and installing engine mounting”, page 35
⇒ “2.3 Removing and installing engine bracket”, page 37
⇒ “2.4 Supporting engine in installation position”, page 40
⇒ “2.5 Adjusting assembly mountings”, page 42 AG. Volkswagen AG d
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1 - Centre hex stud s
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❑ Specified torque and
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tightening sequence
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⇒ page 34
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2 - Engine support
spec
urposes, in part or in wh
❑ Removing and installing
t to the co
⇒ page 37
3 - Bolt
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❑ Renew after removal
❑ Specified torque and
s
tightening sequence
s o
⇒ page 34
cial p
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4 - Bolt
mer
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❑ 40 Nm +90°
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5 - Bracket
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7 - Bolt
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❑ Renew after removal
❑ 20 Nm +90°
8 - Bolt
❑ Renew after removal
❑ 60 Nm +90°
9 - Engine mounting
Caution
Damage
♦ to the mem‐
brane will result in loss of
hydraulic fluid and thus
impair functionality.
❑ The membrane can be found on the underside of the engine mounting ⇒ page 33 .
❑ In the event of damage to the membrane, renew engine mounting.
10 - Pendulum support
❑ Removing and installing ⇒ page 34
32 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
11 - Bolt
❑ Renew after removal
❑ Observe specified sequence when removing and installing ⇒ page 34
❑ Observe specified torque ⇒ page 34
12 - Bolt
❑ Renew after removal
❑ Observe specified sequence when removing and installing ⇒ page 34
❑ Observe specified torque ⇒ page 34
13 - Bolt
❑ Renew after removal
❑ Observe specified sequence when removing and installing ⇒ page 34
❑ Observe specified torque ⇒ page 34
14 - Bolt
❑ Renew after removal
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15 - Bolt rise
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❑ 40 Nm +90°
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16 - Gearbox mounting
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17 - Gearbox support
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18 - Bolt
spec
urposes, in part or in wh
❑ Specified torque ⇒ Power transmission; Rep. gr. 34
t to the co
19 - Bolt
❑ Specified torque ⇒ Power transmission; Rep. gr. 34
rrectne
20 - Support
s
21 - Bolt
s o
cial p
f
❑ Specified torque ⇒ Power transmission; Rep. gr. 34
inform
mer
atio
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Membrane of engine mounting
i
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te
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The membrane -arrow- must not be damaged.
iv
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fo
– If membrane is damaged, renew engine mounting
en
ng
t.
⇒ page 35 .
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Cop py
t. rig
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by
cted agen
Prote AG.
2. Assembly mountings 33
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Pendulum support
Always observe size and property class of the bolt. Different tor‐
que specifications apply.
Caution
As of gearbox production date 28 05 7, Heli-Coil inserts are
installed in the threaded connections to pendulum support in
manual gearboxes 02Q. Identification
gen AG
. Vo⇒ Rep.
lksw gr.
agen AG d 34 a oes
lksw n
Use a bolt with property
db
y Vclass 10.9 for this and all othert ggear‐
o o
ua
boxes. e ran
is tee
or h
ut or
If there is no Heli-Coil
ss
a insert in the 02Q gearbox, use class 8.8 ac
bolts and the corresponding torque setting.
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un
pt
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itte
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Tighten only if pendulum support is bolted to gearbox.
pe
ility
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Always renew after removing.
h re
hole
Specified torque
spec
es, in part or in w
t to the co
Component Specified torque
Bolt A: M10 x 35, property class 40 Nm +90°
8.8
rrectness of i
Bolt A: M10 x 35, property class 50 Nm +90°
l purpos
10.9
Bolt B: M10 x 75, property class 40 Nm +90°
nform
ercia
8.8
m
Bolt B: M10 x 75, property class 50 Nm +90°
a
com
tio
10.9
n in
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te o
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Bolt C: M14 x 1.5 x 70 100 Nm +90°
s
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Pendulum support - tightening sequence
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Removing
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– First unscrew bolt -1-. co Vo
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– Then unscrew bolts -2- and -3-.
AG.
Installing
– First screw in bolts -2- and -3-.
– Then screw in bolt -1-.
Engine bracket - specified torques and tightening sequence
Note
Renew bolts for engine bracket.
– Tighten bolts in 3 stages in the sequence shown:
Stage Bolts Specified torque/turning further angle
1) -1 … 3- 7 Nm
2) -1 … 3- 40 Nm
3) -1 … 3- Turn 180° further
34 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2 Removing and installing engine mount‐
ing
Special tools and workshop equipment required
♦ Spring-type clip pliers - VAS 6362-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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ut ra
♦ Torque wrench (5 to 50ssNm) - V.A.G 1331-
a c
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pt
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itte
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erm
ab
ility
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wit
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h re
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spec
urposes, in part or in wh
t to the co
rrectness
Removing
o
cial p
f in
– Loosen hose clip -4- and remove air hose.
form
mer
atio
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n
c
i
or
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te
sd
iva
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pr
cum
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolt -1-.
– Push washer fluid reservoir filler pipe with filler neck -2- to side.
2. Assembly mountings 35
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -arrows-.
– Disconnect electrical connector -1- for coolant shortage indi‐
cator switch - F66- and push coolant expansion tank to side.
– Unclip coolant hose bracket -1- by pushing to side.
AG. Volkswagen AG d
agen oes
olksw not
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ara
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ris nte
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– Loosen bolt -1-. s
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– Unscrew bolt -2- and nut -3-.
an
d
itte
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ab
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
ility
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(fuel hoses -5- and -6- remain connected).
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– Support engine in its installation position ⇒ page 40 .
ole,
spec
urposes, in part or in wh
t to the co
Note
♦ The assembly mounting may only be removed if the engine is
rrectne
supported with support bracket - 10 - 222 A- !
♦ The engine bracket must be loosened only when the assembly ss o
mounting has been removed.
cial p
f inform
mer
atio
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n
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i
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te
sd
iva
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– Unscrew bolts -1- and -2- and remove connecting bracket.
r
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– Unscrew bolts -3 … 6- and remove engine mounting. . Cop py
rig
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Installing py by
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cted
Install in reverse order of removal, observing the following:
agen
Prote AG.
Caution
The tightening sequence and specified torques for the engine
bracket securing bolts must be strictly adhered to.
36 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fit engine assembly mounting in position. First, tighten bolts
-3- and -6- and then -1- and -2-.
. Volkswagen AG
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– Use the spindle to bring the engine bracket to restVoon
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– Insert bolts -4- and -5- and then tighten them.
au
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– Adjusting assembly mountings ⇒ page 42 .
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Specified torques
itte
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ab
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
pe
ility
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spec
es, in part or in w
2.3 Removing and installing engine bracket
t to the co
Special tools and workshop equipment required
rrectness of i
♦ Hose clamps to 25 mm - 3094-
l purpos
nform
mercia
a
com
tion in
r
te o
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by
♦ Spring-type clip pliers - VAS 6362- Prote
cted AG.
agen
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
2. Assembly mountings 37
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Loosen hose clip -4- and remove air hose.
– Unscrew bolts -arrows-.
– Disconnect electrical connector -1- for coolant shortage indi‐
cator switch - F66- and push coolant expansion tank to side.
– Open quick-release fasteners -A- and -B- of fuel lines.
AG. Volkswagen AG d
agen oes
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ara
ed
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pt
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– Unclip coolant hose bracket -1- by pushing to side.
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es, in part or in w
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Cop py
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by lksw
cted agen
Prote AG.
38 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Loosen bolt -1-.
– Unscrew bolt -2- and nut -3-.
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
(fuel hoses -5- and -6- remain connected).
– Support engine in its installation position ⇒ page 40 .
Note
n AG. Volkswagen AG do
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♦ The assembly mounting yV
o may only be removed if sthe
lks ot engine
gu is
supported withrisupport
se
d b
bracket - 10 - 222 A- ! ara
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♦ ut
The engines abracket must be loosened only when the assembly ra
c
mounting has been removed.
s
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ab
pe
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spec
– Unscrew bolts -1- and -2- and remove connecting bracket.
es, in part or in w
t to the co
– Unscrew bolts -3 … 6- and remove engine mounting.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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– Clamp off coolant hoses using hose clamps to 25 mm - 3094-
um
fo
and remove. To do this, release hose clips -arrows-.
en
ng
t.
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op
– Disconnect connector -3- on radiator outlet coolant tempera‐
C py
t. rig
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ture sender - G83- .
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pyri by
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cted
– Remove nut -1- and bolt -2-, remove right coolant pipe.
agen
Prote AG.
– Remove front right wheel housing liner ⇒ General body re‐
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Front wheel
housing liner .
WARNING
When raising and lowering engine using support bracket -
10-222A- , ensure that no components or hoses are damaged,
overstretched or torn off.
Note
The bolt -1- is accessible through an aperture in the wheel hous‐
ing. Raise and lower engine using spindle of support bracket - 10
- 222 A- to remove or start bolts -2- and -3-.
2. Assembly mountings 39
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts of engine bracket in sequence -3…1-.
– Remove engine bracket upwards.
Installing
Install in reverse order of removal, observing the following:
Caution agen
AG. Volkswagen AG d
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The tightening sequence and specified torques for the engine rised ara
nte
bracket securing bolts must always be followed. Otherwiseutthe
ho eo
ra
engine bracket can be stressed, causing it to break. ss a c
ce
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– Insert engine bracket from above.
rm
ab
pe
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Note
h re
hole
spec
The bolt -1- is accessible through an aperture in the wheel hous‐
es, in part or in w
t to the co
ing. Raise and lower engine using spindle of support bracket - 10
- 222 A- to remove or start bolts -2- and -3-.
rrectness of i
– Initially screw in new bolts hand-tight in the sequence
-1 to 3-.
l purpos
Tightening sequence for engine bracket
nform
ercia
– Tighten bolts in specified sequence to specified torque.
m
a
com
tion in
r
te o
thi
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fo
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t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
– Fit engine assembly mounting in position. First, tighten bolts
-3- and -6- and then -1- and -2-.
– Use the spindle to bring the engine bracket to rest on the as‐
sembly mounting.
– Insert bolts -4- and -5- and then tighten them.
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Add coolant ⇒ page 194 .
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
2.4 Supporting engine in installation posi‐
tion
Special tools and workshop equipment required
40 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Support - 10 - 222 A-
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
♦ Hook - 10 - 222 A /2- thoris nte
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pe
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es, in part or in w
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rrectness of i
♦ Adapter - 10 - 222 A /3-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
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Prote AG.
♦ Adapter - 10 - 222 A /16-
2. Assembly mountings 41
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Adapter - 10 - 222 A /30-
Sequence of operations
– Remove filler pieces from upper edge of left and right wings.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Bulkhead; Removing and installing ple‐
num chamber bulkhead .
– Remove air filter housing ⇒ page 319 .
olksw
– Remove intake hose on turbocharger
swa
⇒. VItem 2ag(page
gen AG
en AG 318) .
does
olk not
V
– by A- with adapter - 10 - 222 A /30-gu,ar
Fit support bracket - 10s-ed222 an
adapter - 10 - 222 A t/3-
ho and adapter - 10 - 222 A /16- as shown
ri tee
or
in illustration. au ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
– Attach hook - 10 - 222 A /2- to support eye and adapter - 10 -
222 A /16- .
rrectness of i
– Take up weight of engine and gearbox on spindles.
l purpos
nf
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orm
m
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2.5 Adjusting assembly mountings Cop py
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Special tools and workshop equipment required cop Vo
by lksw
cted agen
Prote AG.
42 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
. Volkswagen AG
gen AG does
♦ Pliers for spring-type clips - VAS
Vol
ks6362-
wa not
y gu
db ara
rise nte
tho eo
au ra
c
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Sequence of operations
rrectness of i
l purpos
WARNING
nf
ercia
When doing any repair work, especially in the engine compart‐
or
ment, pay attention to the following due to the cramped condi‐
m
m
atio
tions:
om
n in
or c
♦ Route lines of any kind so that the original routing can be
thi
te
restored.
sd
iva
o
r
rp
cu
♦ Ensure that there is sufficient clearance to all moving or
o
m
f
en
ng
hot components.
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
– Remove air filter housing ⇒ page 319 .
lksw
cted agen
Prote AG.
– Loosen hose clip -4- and remove air hose.
Caution
Risk of irreparable damage to electronic components when
disconnecting battery .
♦ Comply with precautions when disconnecting battery .
2. Assembly mountings 43
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Disconnect earth wire -arrow- from battery with ignition switch‐
ed off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
reconnecting battery .
AG. Volkswagen AG d
agen oes
olksw not
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– Remove battery and edbattery tray -arrows-.
b ara
nte
ris
ho eo
aut ra
ss c
Note
ce
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un
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an
d
itte
For reasons of clarity, diagram shows installation position with
y li
erm
ab
fuel filter removed.
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wit
is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
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om
n
c
– Unscrew bolt -1-.
or
n thi
te
sd
a
– Push washer fluid reservoir filler pipe with filler neck -2- to side.
iv
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -arrows-.
– Disconnect electrical connector -1- for coolant shortage indi‐
cator switch - F66- and push coolant expansion tank to side.
44 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unclip coolant hose bracket -1- by pushing to side.
– Loosen bolt -1-.
– Unscrew bolt -2- and nut -3-.
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
(fuel hoses -5- and -6- remain connected).
– Support engine in its installation position ⇒ page 40 .
Note
It is only permissible to loosen the securing bolts for the assembly
mountings if the engine is supported on the support bracket -
10-222 A- .
– Unscrew engine mounting bolts -arrows- in succession and
renew (if not already carried out on installing engine).
G. Volkswage nA n AG d
wage oes
– First screw bolts in loosely.y Volks not
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th
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ab
ility
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spec
es, in part or in w
– Renew gearbox mounting bolts -arrows- in succession (if not
t to the co
already carried out) and screw in hand-tight.
– First screw bolts in loosely.
rrectness of i
Engine mounting
l purpos
nf
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orm
m
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Cop py
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pyri by
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co
45
by lksw
cted agen
Prote 2. Assembly mountings
AG.
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Using an assembly lever between engine bracket and support
arm -1-, adjust position of engine until the specifications listed
below are obtained:
• There must be a distance of -a- = 13.5 mm between engine
support -2- and right longitudinal member.
• The side of the engine support casting -2- must be aligned
parallel to the support arm -1- (dimension -x- must be identical
on both sides).
Note
Distance -a- = 13.5 mm can also be checked with a rod of suitable
size, or similar.
– Tighten bolts for engine mounting.
AG. Volkswagen AG d
Gearbox mounting lksw
agen oes
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– On the gearboxthside,
oris ensure that the edges of the support arm nte
eo
-2- and gearbox
s au support -1- are parallel. ra
c
s
ce
• Dimension -x- must be identical on both sides of mounting.
e
nl
pt
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an
itte
– Tighten bolts for gearbox mounting.
y li
erm
ab
• Ensure that fuel lines are tight. ility
ot p
wit
, is n
• Do not interchange supply line and return line (return line blue
h re
hole
or with blue marking, supply line black).
spec
es, in part or in w
– Observe notes after connecting battery ⇒ Electrical system;
t to the co
Rep. gr. 27 ; Disconnecting and reconnecting battery .
Specified torques
rrectness of i
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
l purpos
nf
ercia
orm
m
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n in
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thi
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t.
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Cop py
t. rig
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by c lksw
cted agen
Prote AG.
46 Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
n AG. Volkswagen AG do
lkswage es n
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yV
3 Engine cover panel
d b ua
ran
ir se tee
tho
u or
⇒ “3.1 Removing
ss and installing engine cover”, page 47
a ac
ce
le
un
3.1 Removing and installing engine cover
pt
an
d
itte
y li
erm
ab
Removing
ility
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wit
is n
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Caution
ole,
spec
urposes, in part or in wh
The engine cover retainer on the cylinder head cover can break
t to the co
if not removed correctly. Always remove engine cover accord‐
ing to following instructions.
rrectne
– Pull engine cover panel upwards out of fasteners in areas of
s
-arrows- and in sequence shown. To do this, grip as far be‐
s o
cial p
neath engine cover panel as possible.
f inform
mer
Installing
atio
om
n
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i
Caution
or
n thi
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iva
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Before installing engine cover panel, check the 4 securing el‐
p
cum
r
fo
ements (ball sockets) in the correct positions. Reset to correct
en
ng
t.
yi
position if necessary. Otherwise the engine cover panel may
Co
op py
be damaged.
t. C rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Press engine cover panel ball sockets into correct position.
– Position engine cover panel on securing points and press cor‐
ners into fasteners.
3. Engine cover panel 47
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block”, page 48
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
50
⇒ “1.3 Assembly overview - poly V-belt drive without air condi‐
tioner compressor”, page 51
⇒ “1.4 Assembly overview - poly V-belt drive with air conditioning
compressor”, page 52
⇒ “1.5 Assembly overview - ancillary bracket”, page 53
⇒ “1.6 Removing and installing sealing flange on pulley end”,
page 53
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
page 56
⇒ “1.8 Removing and installing bracket for ancillaries”, AG. Volkswagen AG d
page 58 lksw
agen oes
n o ot g
yV ua
⇒ “1.9 Removing and installing poly V-belt without
ris
edair conditioner
b ran
tee
compressor”, page 61 ut
ho
or
sa ac
⇒ “1.10 Removing and installing poly V-belt
s
with air conditioner
ce
e
nl
compressor ”, page 61
pt
du
an
itte
y li
⇒ “1.11 Removing and installing tensioner for poly V-belt”,
erm
ab
page 63
ility
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wit
, is n
⇒ “1.12 Removing and installing vibration damper”, page 64
h re
hole
spec
1.1 Assembly overview - cylinder block
es, in part or in w
t to the co
Note
♦ If you discover metal shavings or a large quantity of small rrectness of i
l purpos
metal particles during engine repair, proceed as follows to
prevent further damage:
nform
ercia
♦ Thoroughly clean oil channels.
m
at
♦ Renew engine oil cooler ⇒ page 180 .
om
ion
c
in t
or
his
ate
do
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cum
for
en
ng
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
48 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Cylinder block
❑ Assembly overview -
pistons and conrods
⇒ page 79
❑ Removing and installing
sealing flange and fly‐
wheel ⇒ page 66 .
❑ Removing and installing
crankshaft
⇒ page 76 .
2 - Guide tube
❑ Renew O-ring
3 - Clip
4 - Seals
❑ Renew after removal
5 - Oil filter bracket
❑ Assembly overview
⇒ page 179
6 - Bolt
❑ Renew after removal
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❑ Tightening sequence lksw
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⇒ page 50 . d byV
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❑ 14 Nm +180° horis
eo
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7 - Bolt ss c
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un
❑ 13 Nm
pt
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8 - Thermostat (4/2-way valve)
rm
ab
pe
ility
❑ Thermostat is firmly in‐
ot
wit
stalled in valve.
, is n
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hole
❑ Can only be renewed as
spec
a complete item
es, in part or in w
t to the co
❑ Removing and installing
⇒ page 208
9 - O-ring
rrectness of i
❑ Renew after removal
l purpos
10 - Lifting eye
nform
ercia
11 - Bracket
m
12 - Bolt
com
tion in
r
Specified torque and tightening sequence ⇒ page 53
te o
thi
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13 - Bolt
r
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fo
❑ 20 Nm
en
ng
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op py
14 - Sump
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❑ Clean sealing surface before fitting. copy Vo
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❑ Silicone sealant ⇒ Electronic parts catalogue (ETKA) Prote AG.
15 - Bolt
❑ 15 Nm
1. Cylinder block (pulley end) 49
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Tightening sequence for oil filter bracket
– First, tighten new upper left and lower right bolts.
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– Tighten bolts in 2 stages: ksw
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1- 14 Nm ised b ara
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2- Then, turn 180° further. s aut ra
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1.2 Assembly overview - sealing flange, belt pulley end
nform
mercia
a
1 - Bolt
com
tion in
❑ Renew after removal
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❑ Do not additionally oil
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r
the thread and shoulder
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fo
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❑ 180 Nm +135°
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2 - Crankshaft pulley
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❑ With or without mark co Vo
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(depending on version)
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❑ Contact surface be‐
tween toothed belt pul‐
ley and crankshaft must
be free from oil
❑ Can only be fitted in one
position
3 - Crankshaft oil seal for belt
pulley end
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing ⇒ page 56
4 - Sealing flange at belt pulley
end
❑ Must seat on dowel
pins.
❑ Silicone sealant ⇒ Elec‐
tronic parts catalogue
(ETKA)
❑ Removing and installing
⇒ page 53
50 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
5 - Cylinder block
6 - Dowel pin
7 - Bolt
❑ Specified torque and tightening sequence ⇒ page 51
Sealing flange at belt pulley end - Prescribed torque and tighten‐
ing sequence
– Tighten bolts for sealing flange at belt pulley end in the se‐
quence -1 … 10- in 3 stages as follows:
1. Screw in bolts -1 … 10- by hand until heads make contact.
2. Tighten bolts -1 … 6- in diagonal sequence to 15 Nm.
3. Tighten bolts -7 … 10- to 15 Nm.
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1.3 Assembly overview - poly V-belt drive without air conditioner compressor
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1 - Belt pulley and vibration
un
pt
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ab
❑ Fitting possible in one
pe
ility
position only. The holes
ot
wit
are offset.
, is n
h re
hole
❑ Removing and installing
spec
⇒ page 64
es, in part or in w
t to the co
2 - Alternator
❑ Removing and installing
⇒ Electrical system;
rrectness of i
Rep. gr. 27 ; Alternator
l purpos
3 - Ancillary bracket
Assembly overview
nform
ercia
⇒ page 53
m
a
com
tio
4 - Poly V-belt
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❑ Renew after removal
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iva
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❑ Removing and installing
r
rp
cum
fo
⇒ page 61
en
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
1. Cylinder block (pulley end) 51
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.4 Assembly overview - poly V-belt drive with air conditioning compressor
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
❑ Removing and installing
⇒ page 61
2 - Tensioning element
3 - Belt pulley and vibration
damper
❑ Offset holes make as‐
sembly possible in one
position only
4 - Bolt
❑ Renew after removal
❑ 10 Nm +90°
5 - Dowel sleeves
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❑ Check for correct seat‐ agen oes
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ing in ancillary bracket. d by gu
ara
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6 - Bracket auth eo
ra
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❑ Removing and installing s
ce
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nl
⇒ page 58
pt
du
an
itte
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7 - Bolt
erm
ab
ility
❑ Renew after removal
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❑ 20 Nm +180° h re
hole
spec
8 - Alternator
es, in part or in w
❑ Removing and installing
t to the co
⇒ Electrical system;
Rep. gr. 27
rrectness of i
9 - Air conditioner compressor
l purpos
❑ Removing and installing
⇒ Heating, ventilation, air conditioning system; Rep. gr. 87 .
nf
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10 - Dowel sleeves
orm
m
❑ Check for correct seating in ancillary bracket.
atio
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t.
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Cop py
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Vo
co lksw
by
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Prote AG.
52 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.5 Assembly overview - ancillary bracket
– Install bolts as follows:
♦ Bolts -1- and -2- M10 x 52.
♦ Bolts -3- and -4- M10 x 30.
♦ Bolts -5- and -6- M10 x 60.
– Tighten bolts in 4 stages in the sequence shown:
Stage Bolts Specified torque/turning further angle
1) -1 … 6- Screw in by hand as far as stop
2) -1 … 6- 40 Nm
3) -3- and -4- Turn 45° further
4) -1, 2, 5, 6- Turn 90° further
1.6 Removing and installing sealing flange
on pulley end
Special tools and workshop equipment required
♦ Counter-hold tool - 3415-
AG. Volkswagen AG d
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ab
ility
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hole
spec
♦ Assembly tool - T10053-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder block (pulley end) 53
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench - V.A.G 1332-
Removing
– Remove toothed belt ⇒ page 127 .
– Lock crankshaft pulley -1- in position using counterhold tool -
3415- .
– Unscrew bolt -2-.
– Remove crankshaft pulley -1-.
– Remove sump ⇒ page 167 .
– Unscrew bolts -1 … 10- and carefully remove sealing flange
from the glued joint.
– Remove sealing flange. If necessary, loosen sealing flange
using light blows with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
AG. Volkswagen AG d
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– Remove sealant residue from sealing flange with a rotating
rm
ab
pe
ility
plastic brush (wear protective goggles).
ot
wit
, is n
– Clean sealing surfaces. They must be free of oil and grease.
h re
hole
spec
Installing
es, in part or in w
t to the co
Install in reverse order of removal, observing the following:
rrectness of i
Note
l purpos
♦ Check the expiry date of the sealant.
♦ The sealing flange must be installed within 5 minutes of ap‐
nform
ercia
plying the silicone sealant.
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a
com
ti
♦ The sealant bead must be no thicker than 2 to 3 mm. Excess
on in
sealant can find its way into the sump and block the strainer
r
te o
thi
in the suction line and drip on the sealing surface of the crank‐
s
iva
do
shaft seal.
r
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♦ Before applying sealant bead, cover sealing surface of oil seal
n
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with a clean cloth. Cop py
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Prote AG.
54 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
3 mm). . Volkswage AG n AG d
agen oes
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ab
ility
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spec
urposes, in part or in wh
t to the co
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cial p
f in
– Apply a thin bead of sealant at the edge of the joint between
form
mer
the cylinder block and the sump -arrows-.
atio
om
n
c
i
or
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te
sd
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t.
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Cop py
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pyri by
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co lksw
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Prote AG.
– Apply silicone sealant bead as shown in the illustration to clean
sealing surface of sealing flange.
1. Cylinder block (pulley end) 55
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Thinly coat lower sealing surface -shaded area- on sealing
flange with sealant.
– Fit sealing flange immediately and lightly tighten all bolts.
Note
♦ When fitting sealing flange with oil seal installed use the guide
sleeve - T10053/1- .
♦ Leave the sealant to dry for approx. 30 minutes after assem‐
bly. Only then fill with engine oil.
– Tighten sealing flange securing bolts diagonally and alternate‐
ly. AG. Volkswagen
agen AG do
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– Install crankshaft pulley. by Vol ot g
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– Install sump ⇒ page 167 oris. tee
h
ut or
ac
– Install s a adjust valve timing
toothed belt sand ⇒ page 127 .
ce
e
nl
pt
Specified torques
du
an
itte
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erm
♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,
ab
ility
page 50
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♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
h re
hole
spec
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 165
es, in part or in w
t to the co
1.7 Renewing crankshaft oil seal - belt pulley end
rrectness of i
l purpos
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at
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ion
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ate
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for
en
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t.
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Cop py
t. rig
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Vo
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by c lksw
cted agen
Prote AG.
56 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Special tools and workshop
equipment required
AG. Volkswagen AG d
agen oes
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tho eo
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nl
pt
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spec
es, in part or in w
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♦ Seal puller - 3203- opyri
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c
♦ Counter-hold tool - 3415-
by lksw
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Prote AG.
♦ Assembly tool - T10053-
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
Removing
– Remove toothed belt ⇒ page 127 .
– Lock crankshaft pulley -1- in position using counterhold tool -
3415- .
– Unscrew bolt -2-.
– Remove crankshaft pulley -1-.
1. Cylinder block (pulley end) 57
Caddy 2011 ➤ AG. Volkswagen AG d
4-cylinder diesel engine (1.6 l engine, common agen
ksw rail) - Edition 07.2019
oes
ol not
V y gu
db ara
ise nte
– To guide seal extractor - 3203- , screw thcentre
or bolt into crank‐ eo
shaft as far as stop by hand. ss au ra
c
ce
e
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
nl
pt
du
an
from the outer part and lock in position with the knurled screw.
itte
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erm
ab
– Oil threaded head of seal extractor.
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– Screw oil seal extractor forcibly as far as possible into oil seal.
, is n
h re
hole
– Loosen knurled screw and turn inner part against crankshaft
spec
until the oil seal is pulled out.
es, in part or in w
t to the co
Installing
Install in reverse order of removal, observing the following:
rrectness of i
l purpos
Note
nf
ercia
Do not be additionally oil or grease the oil seal sealing lip.
orm
m
atio
om
– Remove oil residues from crankshaft journal with a clean cloth.
n in
or c
thi
te
sd
iva
– Fit guide sleeve - T10053/1- onto crankshaft journal.
o
r
rp
cu
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m
f
– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
en
ng
t.
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nal.
Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Press oil seal in as far as stop with press sleeve - T10053- and
central bolt.
– Install crankshaft pulley.
– Install and tension toothed belt ⇒ page 127 .
Specified torques
♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,
page 50
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
1.8 Removing and installing bracket for an‐
cillaries
Special tools and workshop equipment required
58 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
tho eo
au ra
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nl
pt
du
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Removing
erm
ab
ility
ot p
– Remove high-pressure pump ⇒ page 302 .
wit
, is n
h re
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
hole
nator .
spec
es, in part or in w
Vehicles with air conditioning system
t to the co
WARNING
rrectness of i
Do not open the air conditioner refrigerant circuit.
l purpos
nform
ercia
– Unbolt air conditioner compressor from ancillary bracket Then,
secure air conditioner compressor to lock carrier ⇒ Heating,
m
at
om
i
ventilation, air conditioning system; Rep. gr. 87 ; Air condi‐
on
c
in t
tioner compressor; Removing and installing air conditioner
or
his
e
compressor .
at
do
priv
c
Continued for all vehicles
um
for
en
ng
t.
yi
– Remove idler pulleys -1- and -2-. Unscrew bolt for toothed belt
Co
op py
guard -arrow-.
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pyri by
Vo
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– Support engine in its installation position ⇒ page 40 .
c by lksw
cted agen
Prote AG.
– Loosen securing bolt for engine bracket -1-.
1. Cylinder block (pulley end) 59
n AG. Volkswagen AG do
lkswage es n
Caddy 2011 d➤by Vo ot g
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ra
4-cylinderhordiesel engine (1.6 l engine, common rail) n-teEdition
ise
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t
au ra
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ss
– Unscrew bolts -6….1- and remove ancillary bracket.
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pt
Installing
an
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ab
Install in reverse order of removal, observing the following:
ility
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♦ Note any fitted sleeves in ancillary bracket and renew missing
is n
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ones if necessary.
ole,
spec
urposes, in part or in wh
♦ Renew all bolts to be tightened with torque angle.
t to the co
♦ Tack engine bracket bolt before tightening ancillary bracket
securing bolt.
rrectness o
cial p
f inform
mer
atio
om
n
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or
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te
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– Tighten securing bolts in sequence -1…6-.
fo
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ng
t.
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– Install high-pressure pump, install toothed belt and adjust . Cop py
valve timing ⇒ page 302 .
t rig
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pyri by
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Prote AG.
– Renew and tighten bolt -1- of engine bracket ⇒ page 32 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator .
– Detach air conditioner compressor from lock carrier, then fit it
to ancillary bracket, and tighten it ⇒ Heating, ventilation, air
conditioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor .
– Installing high-pressure pump ⇒ page 302 .
– Install toothed belt and adjust valve timing ⇒ page 302 .
– Filling/bleeding high-pressure pump/fuel system
⇒ page 268 .
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
♦ ⇒ “1.5 Assembly overview - ancillary bracket”, page 53
♦ Starter; Assembly overview - starter ⇒ Electrical system; Rep.
gr. 27 ; Assembly overview - starter
60 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.9 Removing and installing poly V-belt
without air conditioner compressor
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The poly V-belt repair kit with tools contains the assembly
aut
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tool - ra
T10367- and illustrated instructions. ss c
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Removing
itte
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ab
pe
– Remove noise insulation ⇒ General body repairs, exterior;
ility
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Rep. gr. 66 ; Body front; Noise insulation .
wit
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– Cut through poly V-belt.
hole
spec
es, in part or in w
– Further work sequence is carried out as described in illustrated
t to the co
instructions.
The illustrated instructions accompany the spare part.
rrectness of i
Installing
l purpos
Install in reverse order of removal, observing the following:
If poly V-belt was installed offset:
nform
ercia
– Do not remove poly V-belt.
m
a
com
tion in
– Turn engine at crankshaft. When doing this, guide poly V-belt
r
te o
thi
until it is properly seated on belt pulley.
s
iva
do
r
– Install noise insulation ⇒ General body repairs, exterior; Rep.
rp
cum
fo
gr. 66 ; Body - front; Noise insulation .
en
ng
t.
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op
1.10 Removing and installing poly V-belt with
C py
ht. rig
rig ht
by
air conditioner compressor copy Vo
by lksw
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Prote AG.
Special tools and workshop equipment required
♦ Locking pin - T10060 A-
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
1. Cylinder block (pulley end) 61
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Vehicles with auxiliary heater
– Unscrew bolt -2- from coolant pipe bracket -1- of auxiliary
heater.
– Unscrew bolts -1- of coolant pipes for auxiliary heater -2- from
drive shaft heat shield.
Continued for all vehicles
– Mark running direction of poly V-belt.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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un
pt
– Turn tensioning device in direction of arrow to relieve tension
an
d
itte
on poly V-belt.
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erm
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ility
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ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f in
– Align holes -arrows- with each other. Lock tensioning element
form
mer
using locking pin - T10060 A- . atio
om
– Remove poly V-belt.
n
c
i
or
n thi
e
Installing
t
sd
iva
o
pr
Install in reverse order of removal, observing the following:
um
r
fo
en
ng
t.
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Cop py
t. rig
Note
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pyri by
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♦ Before installing poly V-belt, ensure that all ancillaries (alter‐ Prote AG.
nator, air conditioner compressor) are secure.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.
62 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fit poly V-belt on poly V-belt pulley as shown in illustration.
1- Crankshaft
2- Tensioning element
3- Alternator
4- Air conditioner compressor
On completing work:
– Start engine, and check if belt runs properly.
1.11 Removing and installing tensioner for
poly V-belt n AG. Volkswagen A ge G do
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Special tools and workshop equipment required
by
Vol
k ot g
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♦ Torque wrench (40 to 200 Nm)th-orV.A.G
i
1332- tee
or
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t to the co
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Removing
l purpos
– Remove poly V-belt ⇒ page 61 .
nform
ercia
Notes on hose connections with screw-type clamps
m
⇒ page 246
a
com
tion in
– Open clips -1- and -2- and remove connecting hose.
r
te o
thi
s
iva
– Remove radiator cowl with radiator fan - V7- and remove right
do
r
rp
radiator fan - V35- ⇒ page 218 .
um
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Cylinder block (pulley end) 63
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Undo and remove bolts -arrows- from charge air pipe and de‐
tach connector -1- from charge pressure sender - G31- .
Notes on hose connections with screw-type clamps
⇒ page 246
– Open clamp -2-.
– Detach coolant hose -3- from retainers and remove charge air
pipe.
– Remove air conditioner compressor. Do not disconnect refrig‐
erant lines from air conditioner compressor.
– Refrigerant circuit remains closed.
– Use suitable means to suspend air conditioner compressor on
vehicle body ⇒ Heating, ventilation, air conditioning system;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Unscrew securing bolt -2-.
– Remove tensioning element for poly V-belt -1-.
Installing AG. Volkswagen AG d
agen oes
olksw not
V gu
Install in reverse order of removal, observing the sfollowing:
ed by ara
nte
ri
o eo
– Install poly V-belt ⇒ page 61 . aut
h
ra
c
ss
Specified torques
ce
le
un
pt
an
d
♦ ⇒ “1.4 Assembly overview - poly V-belt drive with air condi‐
itte
y li
rm
ab
tioning compressor”, page 52
pe
ility
ot
wit
, is n
h re
hole
spec
1.12 Removing and installing vibration damp‐
es, in part or in w
er
Special tools and workshop equipment required t to the co
rrectness of i
♦ Torque wrench - V.A.G 1331-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
64 Rep. gr.13 - Crankshaft group
AG. Volkswagen AG d
ksw
agen oes
no
Caddy 2011 ➤
ol
4-cylinder
d by V diesel engine (1.6 l engine, tcommon
gu
ara rail) - Edition 07.2019
ise nte
or e
th
Removing au
or
ac
ss
– Remove front right wheel housing liner ⇒ General body re‐
ce
e
nl
pt
du
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
an
itte
y li
erm
ab
– Remove poly V-belt ⇒ page 48 .
ility
ot p
wit
– Remove cap for vibration damper. , is n
h re
hole
– Unscrew bolts -1- while counterholding on centre bolt.
spec
es, in part or in w
– Remove vibration damper -2-.
t to the co
rrectness of i
l purpos
Installing
Install in reverse order of removal, observing the following:
nform
ercia
• Installation position: hole -arrow- in vibration damper must
m
at
align over protrusion on crankshaft pulley.
om
ion
c
in t
r
Specified torques
o
his
ate
do
riv
♦ ⇒ “1.4 Assembly overview - poly V-belt drive with air condi‐
p
cum
or
tioning compressor”, page 52
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Cylinder block (pulley end) 65
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Cylinder block, gearbox endAG. Volkswagen A
n G do
wage es n
⇒ “2.1 Assembly overview - flywheel”, page olks
y V 66
ot g
b ua
ed ran
⇒ “2.2 Removing and installing flywheel”,
tho
ris page 67 tee
or
au ac
⇒ “2.3 Removing and installing sealing
ss flange on gearbox side”,
ce
le
page 68
un
pt
an
d
itte
2.1 Assembly overview - flywheel
y li
erm
ab
ility
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wit
is n
1 - Bolt
h re
ole,
spec
❑ Renew after removal
urposes, in part or in wh
❑ 60 Nm +90°
t to the co
2 - Dual-mass flywheel
❑ Offset holes make as‐
rrectne
sembly possible in one
position only
ss o
❑ Removing and installing
cial p
f i
⇒ page 67
nform
mer
3 - Sender wheel
atio
om
❑ For engine speed send‐
n
c
i
or
n
er - G28-
thi
te
sd
va
❑ Removing and installing
i
o
pr
cum
⇒ page 68
r
fo
en
ng
t.
yi Co
4 - Engine speed sender - Cop py
G28- ht. rig
rig ht
py by
❑ Removing and installing
co Vo
by lksw
cted
⇒ page 371
agen
Prote AG.
5 - Bolt
❑ 5 Nm
6 - Dowel pin
7 - Adapter
❑ Must seat on dowel
pins.
❑ Do not damage or bend
when assembling.
❑ Installing ⇒ page 67
8 - Sealing flange with oil seal
❑ Renew after removal
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
❑ Removing and installing ⇒ page 68
9 - Bolt
❑ Specified torque and tightening sequence ⇒ page 67
66 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Install intermediate plate.
– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel pins -arrows at bottom-.
Sealing flange on gearbox side - specified torque and tightening
sequence
– Tighten bolts in 2 stages as follows:
Stag Bolts Specified torque
e
. Volkswagen AG
gen AG does
1) -1 … 6- Screw in by hand as far as Vol
kstop
swa not
by gu
2) -1 … 6- In diagonal sequence ris and in stages;
ed ara
nte
final torque 15 Nm
utho eo
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ss
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e
nl
pt
du
an
itte
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erm
ab
2.2 Removing and installing flywheel
ility
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Special tools and workshop equipment required
h re
hole
spec
♦ Counter-hold tool - 3067-
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
♦ Torque wrench - V.A.G 1332-
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Cylinder block, gearbox end 67
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing AG. Volkswagen AG d
agen oes
olksw not
V gu
• Gearbox is removed. d by ara
ise nte
or eo
h
Vehicles with manual gearbox aut ra
c
ss
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
ce
le
un
pt
clutch .
an
d
itte
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rm
ab
Continuation all vehicles pe
ility
ot
– Insert counterhold - 3067- in hole on cylinder block.
wit
, is n
h re
hole
• Do not unscrew bolts with an power impact wrench. Unscrew
spec
them by hand (risk of damage to flywheel).
es, in part or in w
t to the co
Note
rrectness of i
♦ Item A: tighten bolts.
l purpos
♦ Item B: loosen bolts.
nform
ercia
– Unscrew bolts -1-.
m
a
com
ti
Installing
on in
r
te o
thi
Install in reverse order of removal, observing the following:
s
iva
do
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rp
c
Specified torques
um
fo
en
ng
t.
♦ ⇒ “2.1 Assembly overview - flywheel”, page 66
yi Co
Cop py
t. rig
gh ht
yri by
2.3 Removing and installing sealing flange
op Vo
by c lksw
cted agen
on gearbox side
Prote AG.
Special tools and workshop equipment required
♦ Insert tool, 24 mm - V.A.G 1332/11-
♦ Assembly tool - T10134-
68 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Depth gauge - VAS 6082-
♦ Bolt M6×35 (qty. 3)
♦ Bolt M7×35 (qty. 2)
Pressing out sealing flange with sender wheel
• Gearbox is removed.
– Remove flywheel ⇒ page 67 . n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Note auth or
ac
ss
ce
le
For reasons of clarity, the illustrations show the work procedure
un
pt
an
with the engine removed.
d
itte
y li
erm
ab
ility
ot p
– Remove intermediate plate -1- from dowel sleeves
wit
is n
-arrows A-.
h re
ole,
– Guide intermediate plate -1- upwards.
spec
urposes, in part or in wh
t to the co
– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Turn crankshaft on bolt for toothed belt pulley until crankshaft
rrectne
is at “TDC” position ⇒ page 127 .
– Remove sump ⇒ page 167 .
ss o
cial p
f
– Remove engine speed sender - G28- ⇒ page 371 .
inform
mer
atio
om
n
– Unscrew bolts -arrows- for sealing flange -1-.
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Cylinder block, gearbox end 69
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– To press off, screw 3 bolts M6 x 35 into sealing flange -1-
-arrows-.
Note AG. Volkswagen AG d
agen oes
olksw not
yV
The sealing flange -1- is pressed off crankshaftse-3-
d b together with
gu
ara
the sender wheel -2-. hori nte
eo
aut ra
ss c
– Screw bolts alternately into sealing flange not more than / 1
ce
e
2
nl
pt
du
turn at a time.
an
itte
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erm
ab
– Remove sealing flange -1- together with sender wheel -2-.
ility
ot p
wit
Pressing in sealing flange with sender wheel
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing
rrectness of i
lip support ring -2-. This support ring serves as a fitting sleeve
and must not be removed prior to installation.
l purpos
♦ Sealing flange and sender wheel -1- must not be separated or
turned after removal from packaging.
nform
ercia
♦ The sender wheel -1- is held in its installation position on the
m
at
om
locating pin of the assembly tool - T10134- ⇒ page 70 .
ion
c
in t
or
♦ Sealing flange and oil seal form one unit and must only be
his
ate
renewed together with the sender wheel.
do
priv
cum
or
♦ The assembly tool - T10134- is held in its position relative to
f
en
ng
t.
yi
the crankshaft by a guide pin inserted into a hole in the crank‐
Co
op py
shaft ⇒ page 70 . t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
Set-up of assembly tool - T10134- :
AG.
A - Clamping surface
B - Nut
C - Assembly housing
D-
Locating pin
E - Hexagon socket head bolt (qty. 2)
F - Guide pin for petrol engines (red knob)
G-
Guide pin for diesel engines (black knob)
H - Knurled screws (qty. 3)
I - Inner part
70 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Fitting sealing flange with sender wheel on assembly tool -
T10134- :
– Screw on nut -B- until just before it touches the clamping sur‐
face -A- of the threaded spindle.
– Clamp assembly device - T10134- at clamping surface -A- of
threaded spindle in a vice -1-.
– Push assembly housing -C- downwards until it rests against
nut -B-. en AG. V
olkswagen AG
ag does
lksw not
• Inner part of assembly tool and assembly
yV
o
housing must be at gu
db ara
same height. orise nte
th eo
s au ra
c
s
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
– If fitted, remove securing clip -arrow- from new sealing flange
hole
spec
-1-.
es, in part or in w
t to the co
Note
rrectness of i
Do not take the sender wheel out of the sealing flange or rotate it
l purpos
out of position.
nform
mercia
at
om
ion
c
in t
or
his
te
– Place sealing flange with front side facing down on a clean
a
do
riv
level surface.
p
cum
for
en
ng
t.
– Push sealing lip support ring -1- downwards in op
yi Co
-direction of arrow- until it rests against flat surface.
C py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Cylinder block, gearbox end 71
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.
– Place sealing flange -1- with front side facing downwards onto
assembly tool - T10134- so that locating pin -D- is seated in
hole -3- in sender wheel hole -2-.
• The sealing flange must rest flat against the assembly tool.
• Only 2 of the 3 knurled screws -H- can be screwed in.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
– Screw knurled screws -H- into sealing flange -1-. ss c
ce
le
un
pt
– Press sealing flange -1- and sealing lip support ring -2- against
an
d
itte
surface of assembly tool - T10134- whilst tightening knurled
y li
erm
ab
screws.
ility
ot p
wit
– This prevents the locating pin from slipping out of the sender
is n
h re
wheel hole.
ole,
spec
urposes, in part or in wh
– When installing sealing flange, ensure that sender wheel re‐
t to the co
mains fixed in assembly tool.
rrectness
Mounting assembly tool - T10134- with sealing flange -1- on
o
cial p
f
crankshaft flange:
inform
mer
• The crankshaft flange must be free of grease and oil.
atio
om
• Engine is at “TDC” position ⇒ page 127 .
n
c
i
or
n thi
e
– Screw on nut -B- until it reaches end of threaded spindle.
t
sd
iva
o
pr
– Press threaded spindle of assembly tool - T10134- in
um
r
fo
en
ng
-direction of arrow-, until nut -B- rests against assembly hous‐
t.
yi Co
ing -C-. ht. Cop py
rig
rig ht
– Align flat side of assembly housing to sealing surface of cyl‐ py by
co Vo
inder block on sump side.
by lksw
cted agen
Prote AG.
72 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Attach assembly tool - T10134- together with sealing flange
-1- to crankshaft flange -2-.
– To do this, screw hexagon socket head bolts -E- into crank‐
shaft flange (approx. 5 full turns) using a hexagon key.
– Push guide pin for diesel engines (black knob) -G- into crank‐
shaft flange.
– To guide sealing flange -1-, screw two M6×35 mm bolts -2-
into cylinder block.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
Mounting assembly tool - T10134-
ss with sealing flange -1- on c
ce
crankshaft flange:
e
nl
pt
du
an
itte
• The crankshaft flange must be free of grease and oil.
y li
erm
ab
ility
• Engine is at “TDC” position ⇒ page 127 .
ot p
wit
, is n
– Screw on nut -B- until it reaches end of threaded spindle.
h re
hole
spec
– Press threaded spindle of assembly tool - T10134- in
es, in part or in w
-direction of arrow-, until nut -B- rests against assembly hous‐ t to the co
ing -C-.
– Align flat side of assembly housing to sealing surface of cyl‐
rrectness of i
inder block on sump side.
l purpos
– Attach assembly tool - T10134- together with sealing flange
-1- to crankshaft flange -2-.
nf
ercia
or
– To do this, screw hexagon socket head bolts -E- into crank‐
m
m
atio
shaft flange (approx. 5 full turns) using a hexagon key.
om
n in
or c
– Push guide pin for diesel engines (black knob) -G- into crank‐
thi
te
shaft flange.
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
2. Cylinder block, gearbox end 73
n AG. Volkswagen AG do
lkswage es n
Caddy 2011 ➤ byV
o ot g
ua
ed ran
4-cylinder diesel engine (1.6 l engine, common hor rail) - Edition 07.2019
is tee
ut or
a ac
ss
– To guide sealing flange -1-, screw two M6×35 mm bolts -2-
ce
e
nl
into cylinder block.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Bolting assembly tool - T10134- onto crankshaft flange:
nf
ercia
– Push assembly housing -C- by hand in -direction of arrow- until
orm
sealing lip support ring -1- rests against crankshaft flange
m
atio
m
-2-.
o
n in
or c
thi
– Make sure that guide pin for diesel engines (black knob) -G-
te
sd
a
is properly seated in hole in crankshaft. This ensures that the
iv
o
r
rp
cu
sender wheel reaches its final installation position.
o
m
f
en
ng
t.
yi Co
Cop py
. rig
Note
t
gh ht
pyri by
Vo
co lksw
by
cted
Do not insert the guide pin for petrol engines (red knob) in the
agen
Prote AG.
threaded hole of the crankshaft.
– Tighten the two hexagon socket head bolts of assembly tool
hand-tight.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly housing -C-.
Pressing sender wheel onto crankshaft flange using assembly
tool - T10134- :
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.
• After the nut has been tightened to 35 Nm, a small air gap must
still be present between cylinder block and sealing flange -1-.
Checking sender wheel installation position on crankshaft:
– Screw on nut -B- until it reaches end of threaded spindle.
– Unscrew the two bolts -2- from cylinder block.
– Pull guide pin for diesel engines (black knob) -G- out of crank‐
shaft flange.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
flange.
– Remove sealing lip support ring.
74 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
agen o
– Position depth gauge - VAS 6082-
Vol
ksw on crankshaft flange -2-.
es n
ot g
by ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Measure distance -a- between crankshaft flange -2- and send‐
rrectness of i
er wheel -1-.
l purpos
• Specification: dimension -a- = 0.5 mm
– If specification is not achieved, press sender wheel further in
nf
ercia
⇒ page 75 .
orm
m
atio
– If specification is achieved, proceed with subsequent work
om
steps ⇒ page 75 .
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
Re-pressing sender wheel: py by
co Vo
by lksw
cted agen
– Secure assembly tool - T10134- on crankshaft flange. Prote AG.
– Make sure that locating pin of assembly tool - T10134- is prop‐
erly seated in sender wheel hole.
– Tighten hexagon socket head bolts -E- by hand.
– Push assembly tool - T10134- by hand against sealing flange
-1-.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly tool - T10134- .
– Push guide pin for diesel engines (black knob) -G- into crank‐
shaft flange.
– Screw knurled screws -H- into sealing flange -1-.
– To guide sealing flange, screw two M6×35 mm bolts -2- into
cylinder block.
– Tighten nut -B- of assembly tool - T10134- to 40 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 74 .
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 74 .
Assembling
Assembly is carried out in reverse sequence; note the following:
Specified torques
♦ ⇒ “2.1 Assembly overview - flywheel”, page 66
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 165
2. Cylinder block, gearbox end 75
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 76
⇒ “3.2 Crankshaft dimensions”, page 77
⇒ “3.3 Renewing needle bearing in crankshaft”, page 77
3.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5
❑ For bearing cap without
oil groove.
❑ for cylinder block with oil
groove
❑ Do not interchange
used bearing shells
. Volkswagen AG
(mark). swa
gen AG does
k not
Vol gu
2 - Bolt by ara
ed nte
ris
❑ Renewaafter
ut
ho
removal eo
ra
s c
❑ To measure radial clear‐
s
ce
le
ance, tighten to 65 Nm
un
pt
an
d
but not further.
itte
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rm
ab
❑ 65 Nm +90°
pe
ility
ot
wit
3 - Bearing cap
, is n
h re
❑ Bearing cap 1: belt pul‐
hole
spec
ley end.
es, in part or in w
t to the co
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers
rrectness of i
❑ Bearing shell retaining
lugs in cylinder block
l purpos
and bearing caps must
align.
nform
ercia
4 - Thrust washer
m
❑ For bearing cap 3
com
tion in
❑ Note fixing arrangement
r
te o
thi
s
iva
5 - Bearing shell 3
do
r
rp
cum
❑ For bearing cap without
fo
en
ng
oil groove.
t.
yi Co
Cop py
❑ for cylinder block with oil ht. rig
rig ht
groove py by
co Vo
by lksw
cted
❑ Do not interchange
agen
Prote AG.
used bearing shells (mark).
6 - Needle bearing
❑ Renew after removal
❑ Only vehicles with dual clutch gearbox.
❑ Removing and installing ⇒ page 77
7 - Crankshaft
❑ With toothed belt sprocket for oil pump drive. Toothed belt sprocket is not available as separate part.
❑ Axial clearance new: 0.07 to 0.17 mm, wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage , new: 0.03 to 0.08 mm; wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 77 .
76 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
8 - Thrust washer
❑ For cylinder block, bearing 3
3.2 Crankshaft dimensions
(Dimensions in mm)
Crankshaft Conrod
main journal ∅ journal ∅
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
3.3 Renewing needle bearing in crankshaft
Special tools and workshop equipment required
♦ Counter support, e.g. KUKKO 22-1 - VAS 251 621-
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♦ Internal puller, e. g. KUKKO 21-2 - VAS lk251
swa 605-
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♦ Drift - VW 207 C-
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3. Crankshaft 77
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove gearbox ⇒ Rep. gr. 34 ; Removing and installing
gearbox; Removing gearbox .
• The front edges of the inner puller must be free of chips.
– Pull out needle bearing -1- with internal puller, e.g. KUKKO
21-2 - VAS 251 605- -A- and counter support, e.g. KUKKO
22-1 - VAS 251 621- -B- in direction of -arrow- from crankshaft
-2-.
• The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.
Installing
Install in reverse order of removal, observing the following:
– Clean bearing seat in crankshaft.
– Coat bearing seat in crankshaft with thin layer of commercially
available grease.
– Drive needle bearing into crankshaft to installation depth using
drift - VW 207 C- .
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Installation depth
hole
spec
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Installation depth: dimension -a- = 1.5 mm … 1.8 mm
t to the co
Note
rrectness of i
♦ Renew needle bearing after each removal.
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♦ If the needle bearing is inadvertently driven in too far, it must
nform
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be renewed because it will be damaged when it is pulled out
again.
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78 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 Pistons and conrods
⇒ “4.1 Assembly overview - pistons and conrods”, page 79
⇒ “4.2 Checking pistons and cylinder bores”, page 81
⇒ “4.3 Piston and cylinder dimensions”, page 82
⇒ “4.4 Separating new conrod”, page 82
⇒ “4.5 Measuring piston projection at TDC”, page 83
⇒ “4.6 Checking radial clearance of conrods”, page 84
⇒ “4.7 Removing and installing oil spray jets”, page 85
4.1 Assembly overview - pistons and conrods
1 - Conrod bolt
❑ Renew after removal
❑ Oil threads and contact
surface
❑ Use old bolt for measur‐
ing radial clearance.
❑ 30 Nm +90°
2 - Conrod bearing cap
❑ The conrod bearing cap
only fits in one position
and only on the appro‐
priate conrod due to the
breaking procedure
(cracking) separating
the cap from the conrod.
❑ Mark cylinder allocation
in colour -B-. en AG. Volkswagen AG
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3 - Bearing
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❑ Fitting position
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⇒ page 81
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shells for re-installation
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but not on bearing sur‐
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face.
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❑ Renew bearing shells
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worn down to base lay‐
er.
❑ Note version: upper
rrectness of i
bearing shell (towards
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piston) made of a more
wear-resistant material.
Identification on new
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bearing shells: black line on bearing surface in area of joint
m
❑ Ensure firm seating
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com
tion in
4 - Connecting rod
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❑ Renew as set only.
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❑ With industrially cracked conrod bearing cap
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❑ Separate new conrod ⇒ page 82
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4. Pistons and conrods 79
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition g07.2019
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❑ Axial clearance, wear limit: 0.37 mm tho eo
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❑ Measuring radial clearance ⇒ page 84 ss c
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5 - Locking ring
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❑ Renew after removal
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6 - Piston pin
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❑ If difficult to move, heat piston to approx. 60°C.
hole
spec
❑ Remove and install using drift - VW 222 A- .
es, in part or in w
t to the co
7 - Piston
❑ With combustion chamber.
rrectness of i
❑ Mark installation position and cylinder number ⇒ page 80 .
❑ Checking ⇒ page 82
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❑ Install using piston ring clamp.
❑ Piston and cylinder dimensions ⇒ page 82 .
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❑ Measuring cylinder bore ⇒ page 82
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❑ Measuring piston projection at “TDC” ⇒ page 83
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❑ Measuring ring gap ⇒ page 81
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❑ Measuring ring-to-groove clearance ⇒ page 81
9 - Piston ring
❑ Oil scraper ring
❑ Offset gap 120° relative to lower compression ring
❑ Use piston ring pliers to remove and install.
❑ Measuring ring gap ⇒ page 81
❑ Measuring ring-to-groove clearance ⇒ page 81
Installation position and allocation of piston to cylinder
• If worn pistons are to be reinstalled, mark their allocation to
the cylinder on the piston crown. Only use paint for this.
• Arrow on piston crown points to pulley end -arrow-.
80 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Installation position of bearing shells in conrods
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– Centre bearing shells on conrod and on conrod kbearing cap. does
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• Dimension -a- must be identical on both isides.
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4.2 Checking pistons and cylinder bores
Special tools and workshop equipment required
rrectness of i
♦ External micrometre 75 - 100 mm - VAS 6071-
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Measuring piston ring gap
AG.
– Push piston ring at right angles to cylinder wall from above
down into cylinder bore to approx. 15 mm from bottom end of
cylinder.
– Push in using a piston without piston rings.
Piston ring New Wear limit
mm mm
1st compression ring 0.20 … 0.40 1.00
2nd compression ring 0.20 … 0.40 1.00
Oil scraper ring 0.25 … 0.50 1.00
Measuring ring-to-groove clearance
– Clean annular groove of piston before check.
Piston ring New Wear limit
mm mm
1st compression ring 0.06 … 0.09 0.25
2nd compression ring 0.05 … 0.08 0.25
Oil scraper ring 0.03 … 0.06 0.15
4. Pistons and conrods 81
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Checking piston
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
ton pin axis with a 75 to 100 mm external micrometer.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension ⇒ page 82
Note
Piston must be changed if piston shaft reveals cracking.
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Cylinder bores must not be measured when the cylinder block is
un
pt
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secured to engine and gearbox support - VAS 6095A- , as meas‐
itte
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urements may be incorrect.
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– Measure at three points -c-, in direction -a- and direction -b-.
h re
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spec
• Maximum deviation from nominal dimension: 0.10 mm.
urposes, in part or in wh
t to the co
Nominal dimension ⇒ page 82
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4.3 Piston and cylinder dimensions
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Piston ∅ Cylinder bore ∅
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Basic di‐ mm 79.353 79.5
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Sequence of operations
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Note
♦ To avoid damage, only clamp the conrod lightly in a vice and
use protective jaw covers.
♦ On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
– Clamp conrod -1- below dashed line.
– Unscrew bolts -2- approx. 5 turns.
82 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Using a plastic hammer, carefully knock against conrod bear‐
ing cap -1- in direction of -arrow- until it is loose.
4.5 Measuring piston projection at TDC
Special tools and workshop equipment required
♦ Measuring tool - VW382-
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♦ Measuring plate - VW 385/17-
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♦ Dial gauge - VAS 6079-
or
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Test sequence
♦ Piston projection at TDC must be measured on all pistons
when installing new pistons or a short engine.
4. Pistons and conrods 83
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ If you have measured the piston projection and it is not same
for all pistons, use the highest value to determine the correct
gasket size.
♦ Depending on piston projection, fit the appropriate cylinder
head gasket according to following table.
♦ Turn the engine in an clockwise direction to carry out the
measurement.
olkswagen AG
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– Secure dial gauge - VAS 6079- with measuring bridge -olkswag does
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VW 382/7- and measuring plate -VW 385/17- to cylinder
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♦ To measure the piston projection at top dead centre, turn the
ab
ility
crankshaft clockwise.
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♦ If different values are determined during the projection meas‐
h re
hole
urement, use the largest dimension for selecting the gasket.
spec
es, in part or in w
t to the co
– Measure the projection of each piston at the two points marked
with -arrows- (at the rear side and front side of the piston seen
in the longitudinal direction of the engine).
rrectness of i
– Install the appropriate cylinder head gasket depending upon
l purpos
piston projection, according to following table:
Piston projection over upper Identification
nf
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o
edge of cylinder block in mm Holes/notches
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0.91 … 1.00 1
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1.01 … 1.10 2
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1.11 … 1.20 3
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ment, use the largest dimension for selecting the gasket.
AG.
4.6 Checking radial clearance of conrods
Special tools and workshop equipment required
♦ Plastigage
Test sequence
– Remove conrod bearing cap. Clean bearing cap and bearing
journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
– Fit conrod bearing cap and tighten, but do not tighten with
turning angle. Do not rotate crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• Wear limit: 0.08 mm
– Renew conrod bolts.
84 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Specified torques
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 79
4.7 Removing and installing oil spray jets
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
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spec
es, in part or in w
♦ Hexagon key - T10545-
t to the co
rrectness of i
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nf
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orm
m
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Prote AG.
4. Pistons and conrods 85
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove sump ⇒ page 167 .
– Turn crankshaft in direction of engine rotation until respective
pressure relief valve and oil spray jets are accessible.
Caution
Risk of damage to oil spray jets caused by deformation.
• Do not bend oil spray jets.
– Unscrew pressure relief valve -1- using Torx bit T40 -
T10545- .
– Remove oil spray jets -2-.
Installing
Install in reverse order of removal, observing the following:
– Align guiding edge of oil spray jet with machined surface of
cylinder block.
Specified torques
Component Specified torque
Oil spray jet with 24 Nm
pressure relief
valve
AG. Volkswagen AG d
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86 Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
15 – Cylinder head, valve gear
1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 87
⇒ “1.2 Assembly overview - cylinder head cover”, page 89
⇒ “1.3 Removing and installing cylinder head”, page 91
⇒ “1.4 Removing and installing cylinder head cover”, page 106
⇒ “1.5 Removing and installing injector seals”, page 111
⇒ “1.6 Removing and installing vacuum pump”, page 114
⇒ “1.7 Checking compression”, page 115
1.1 Assembly overview - cylinder head
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❑ To prevent thordamage
is
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glow plugs,
s au always ra
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place cylinder head on a
s
ce
le
soft foam surface after
un
pt
an
d
removal ⇒ page 89 .
itte
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❑ After renewing, renew ab
ility
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entire coolant. wit
is n
❑ Check for distortion
h re
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⇒ page 89 .
spec
urposes, in part or in wh
❑ Removing and installing
t to the co
⇒ page 91
2 - Washer
rrectne
3 - Cylinder head bolt
❑ Before installing, place
ss
washers in cylinder
o
cial p
f i
head
nform
⇒ Item 2 (page 87) .
mer
atio
❑ Specified torque and
om
tightening sequence
c
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⇒ page 88
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4 - Oil pressure switch - F1-
p
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❑ Identification: green
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❑ 0.5 bar
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❑ If seal is leaking, nip
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❑ Checking ⇒ page 185
❑ 22 Nm
5 - Bolt
❑ 20 Nm
6 - Lifting eye
7 - Glow plug
❑ 18 Nm
8 - Seal
❑ Renew after removal
1. Cylinder head 87
Caddy 2011 ➤ agen
AG. Volkswagen AG d
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4-cylinder diesel engine (1.6 l engine, common
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Vol rail) - Edition 07.2019 not gu
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9 - Vacuum pump au
th e or
ac
ss
10 - Bolt
ce
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un
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❑ 10 Nm
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11 - Clip
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12 - Radiator outlet coolant - G62-
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13 - Seal ole,
spec
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❑ Renew after removal
t to the co
14 - Bolt
❑ 10 Nm
rrectne
15 - Coolant hose connection
ss
16 - Seal
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❑ Renew after removal
nform
mer
17 - Bolt
atio
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❑ 25 Nm
n
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18 - Lifting eye
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19 - Cylinder head gasket
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❑ Renew after removal
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❑ Observe identification ⇒ page 89 .
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❑ After renewing, renew entire coolant.
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20 - Hall sender - G40-
❑ For camshaft position.
❑ Removing and installing ⇒ page 372
21 - Bolt
❑ 10 Nm
Cylinder head - specified torque and sequence
– Tighten bolts in stages in the sequence shown.
Stage Bolts Specified torque
1) -1 … 10- 35 Nm
2) -1 … 10- 60 Nm
3) -1 … 10- Turn 90° further
4) -1 … 10- Turn 90° further
88 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Glow plugs -arrows- project out of cylinder head.
Glow plugs -arrow- project out of cylinder head. After removal, the
cylinder head must not be placed on the glow plugs. If necessary,
remove glow plugs ⇒ page 369 .
Checking cylinder head for distortion
AG. Volkswagen AG d
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Special tools and workshop equipment required
e
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♦ Straight edge 500 mm - VAS 6075-
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ab
ility
♦ Feeler gauge -1-
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spec
es, in part or in w
t to the co
Note
Reworking diesel cylinder heads is not permissible.
rrectness of i
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Cylinder head gasket identification
1- Part number
nf
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2- Holes
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m
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3- Ignore
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♦ Different thicknesses of cylinder head gasket are fitted de‐
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install new gasket with same identification.
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♦ Piston projection at TDC must be determined when installing
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Prote AG.
new pistons or a short engine ⇒ page 79 .
1.2 Assembly overview - cylinder head cover
1. Cylinder head 89
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Bolt
❑ 5 Nm
2 - High-pressure accumulator
❑ With injection pipes.
❑ Do not attempt to bend
injector pipes to a differ‐
ent shape.
3 - Bolt
❑ 22 Nm
4 - Injector
❑ Piezo injector
❑ Removing and installing
⇒ page 290
5 - Bolt
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❑ Specified torque ed by
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⇒ page 280 horis nte
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6 - Clamping piece ss c
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❑ One clamping piece for
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2 injectors.
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7 - Bush
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❑ Fastening for high-pres‐
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hole
spec
❑ Renew if damaged
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8 - Seal
❑ Renew after removal
9 - Seal rrectness of i
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❑ Renew after removal
10 - Cap
nform
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11 - Cylinder head cover
m
❑ Removing and installing ⇒ page 106
com
tion in
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12 - Seal
thi
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❑ Renew if damaged or leaking
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14 - Wiring guide
15 - Heat shield
90 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Tightening sequence for cylinder head cover
– Tighten cylinder head cover bolts in the sequence -1 to 6-.
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♦ Guide pin - 3070-
♦ Diesel injection pump locking pin - 3359-
♦ Crankshaft stop - T10050-
♦ Counter-hold tool - T10051-
♦ Puller - T10052-
1. Cylinder head 91
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Socket XZN 10 - T10385-
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♦ Torque wrench - V.A.G 1331-
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♦ Torque wrench - V.A.G 1332-
l purpos
♦ Socket set 1/4", 22-piece - VAS 5528-
nform
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♦ Engine bung set - VAS 6122-
m
♦ Drip tray for workshop hoist - VAS 6208-
com
tion in
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♦ Vehicle diagnostic tester
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92 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Release lever - 80 - 200-
♦ Ratchet ring spanner - T10384-
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♦ Contour blade set - VAS 852 005- (not illustrated) or commer‐
cially available CERAN surface scraper
1. Cylinder head 93
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
♦ All cable ties which are opened or cut through when cylinder
head is removed must be fastened in the same position when
cylinder head is installed.
♦ All connectors which are separated during disassembly must
be reconnected in the original position when installing.
WARNING
When doing any repair work, especially in the engine compart‐
ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route lines of any kind so that the original routing can be agen
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spec
urposes, in part or in wh
remove glow plugs ⇒ page 369 .
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Removing
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– Remove plenum chamber bulkhead ⇒ General body repairs;
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Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
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– Remove air filter housing with air mass meter and connecting
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pipe ⇒ page 318 .
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– Detach vacuum line -2- from vacuum pump -1-.
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– Detach these connectors:
♦ -1- Exhaust gas temperature sender 3 - G495-
♦ -2- Exhaust gas temperature sender 1 - G235-
♦ -3- lambda probe - G39-
94 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull out wiring connector -1- for exhaust gas temperature
sender 4 - G648- from bracket -2- behind battery, release and
separate.
– Guide lines out of brackets on plenum chamber bulkhead and
on turbocharger.
– Disconnect connector -2- from pressure differential sender -
G505- .
– Unscrew bolts -3- and -4-.
– Unclip lines for pressure differential sender - G505- from upper
toothed belt guard together with bracket
wage -1-.
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1. Cylinder head
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -1- for pressure differential sender - G505-
bracket.
– Remove pressure differential sender - G505- bracket.
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– Open clip and pull off fuel supply line -arrow- from high pres‐
sure pump.
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– Unclip coolant hose bracket -1- by pushing it to one side.
96 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Loosen bolt -1-.
– Unscrew bolt -2- and nut -3-.
– Remove fuel filter with bracket.
– Collect any escaping fuel.
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– Unscrew bolt -arrow-. Place the filler neck for washer fluid res‐
t to the co
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– Unscrew bolt -arrow- (captive bolt). Twist intake hose -A-
clockwise out of its holder and remove it.
– Remove cylinder head cover ⇒ page 106 .
1. Cylinder head 97
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unclip vacuum lines -1- and -2-.
– Pull locking device to one side -arrow- and pull off changeover
valve for exhaust gas recirculation cooler - N345- -3- down‐
wards and place to one side.
– Pull off vacuum line -arrow-.
– Lay vacuum lines to side.
– Unbolt connection of vacuum line -arrow-.
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– Unclip engine pre-wiring harness from bracket -arrow-.
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98 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull connector -2- off throttle valve module - GX3- .
– Open clip -3- and pull off charge air hose.
– Unscrew bolt from oil dipstick connection -4-.
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– Separate electrical connector -1- on oil pressure switch - F1- .
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– Unscrew bolt -arrow-.
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– Unscrew bolts -2-, -5- and -arrows-. yri
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– Free electrical lines and hoses on left charge air pipe.
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– Loosen hose clip -3- and remove left charge air pipe.
1. Cylinder head 99
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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– To create space for removing and installing the oil supply line
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with turbocharger support, remove fastening clip -1- between
particulate filter and turbocharger.
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– Unscrew bolt -1-.
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– Loosen securing nuts above particulate filter bracket -1- using
ring ratchet spanner - T10384- .
– Unscrew securing nuts -2- for particulate filter bracket on
crankcase.
100 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Now you can access the bolt of the retaining clamp -arrow- for
the oil return line on the turbocharger support. Unscrew bolt
-arrow-.
– Remove connecting pipes -A- leading to cooler for exhaust
gas recirculation.
– Remove oil supply line and turbocharger support
⇒ page 189 .
– Drain coolant ⇒ page 194 .
– Remove coolant hoses from connections, loosen hose clips
-1- and -2- for this.
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– Detach connector -arrow- for Hall sender - G40- .
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– Support engine in its installation position ⇒ page 40 .
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– Removing engine mounting ⇒ page 35 .
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– Remove engine bracket ⇒ page 37 .
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– Removing toothed belt from camshaft and high-pressure
pump ⇒ page 127 .
Vehicles with fully enclosing toothed belt guard
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The fully enclosing toothed belt guard is bonded, so it is destroyed
m
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– Removing rear toothed belt guard (fully enclosing)
s
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⇒ page 120 .
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AG.
1. Cylinder head
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolt -arrow- of rear toothed belt guard.
– Remove toothed belt tensioning roller.
– Install engine bracket again, tightening old bolts by hand
⇒ page 37 .
– Install engine mounting again, tightening old bolts by hand
⇒ page 35 .
– Remove support device - 10 - 222 A- .
– Remove camshaft sprocket from hub.
– Counterhold hub with counterhold - T10051- and release hub
bolt -1-.
– Unscrew hub bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.
– Tighten securing bolts -1-.
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– Loosen bolts in the sequence -1 … 10-.
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– Unscrew bolts in the sequence -1 … 10-.
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Note
s
♦ A second mechanic is required to remove the cylinder head.
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nform
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i
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te
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102 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Caution
Risk of damage to glow plug pins -arrow- when cylinder head
is being lowered.
♦ Do not lay removed cylinder head with installed glow plugs
down on sealing surface, as glow pins -arrow- project past
sealing surface.
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1. Cylinder head 103
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Caddy 2011 oris ➤
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4-cylinder
aut diesel engine (1.6 l engine, common rail) - Edition ra
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Install in reverse order of removal, observing the following:
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♦ Do not use sandpaper, grinding wheels, abrasive or scour
t to the co
pads or any other sanding or abrasive media.
♦ Sealing surface (see photo) must not project.
rrectness of i
♦ Discolouration (dark spots, see photo) need not be removed.
l purpos
♦ When removing the sealant residue, make sure no loose par‐
ticles get into the open channels of the engine.
nform
ercia
♦ Ensure that all adjacent workspaces are clean, and that none
m
of the above mentioned sanding or abrasive media are used.
at
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secondary damage such as, for example, damage to the tur‐
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Risk of eye injury caused by sealant residue. Prote
cted AG.
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• Wear protective goggles.
– Only remove sealant residue from cylinder head and cylinder
block using scraper - VAS 852 005- or a commercially availa‐
ble ceramic glass scraper.
• The sealing surfaces must not be damaged.
• There must be no oil or coolant in the bolt pockets.
• Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
• If a new cylinder head is installed, contact surfaces between
roller rocker fingers and running surface of cam must be oiled.
• When renewing the engine/cylinder head, note that the plug
in the cylinder head must be renewed. This plug seals the oil
passage against the exterior.
– Remove any loose remains using a lint-free cloth.
Note
♦ Proceed with extreme caution. The assistance of a second
mechanic is vital.
♦ Tensioning roller must be pushed onto studs when fitting cyl‐
inder head.
♦ If the cylinder head gasket or cylinder head has been replaced,
select a new cylinder head gasket according to the number of
holes on the old cylinder head gasket.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be selected by measuring the
piston projection at “TDC” ⇒ page 79 .
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
104 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Before fitting cylinder head, remove crankshaft stop and turn
crankshaft opposite direction of rotation until all pistons are
nearly uniformly below TDC.
– Note cylinder head gasket identification:
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– To centre, screw guide pins - 3070/9- into outer threaded holes
on intake side.
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1. Cylinder head 105
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Guide cylinder head into toothed belt guard and push tension‐
ing roller onto stud. When doing this, cylinder head must not
scrape over dowel sleeves -A-.
– Fit cylinder head.
– Insert cylinder head bolts and screw in by hand until stop is
reached.
– Unscrew guide pins - 3070/9- Athrough bolt holes in cylinder
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– Carry out road test and read all event memories ⇒ Vehicle
diagnostic tester.
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 89
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♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
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♦ Torque wrench - V.A.G 1410-
106 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Socket - T40055-
Removing
Note safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 8 .
Observe instructions for working on fuel system ⇒ page 5 .
– Remove noise insulation at injectors.
– Remove injectors ⇒ page 290 .
Caution
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connecting the connectors.agOtherwise
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– Position pliers - 3314- with groove -arrow A- on support sleeve
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shoulder -arrow B-.
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1. Cylinder head 107
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Open heat shield gaiter -1- from charge pressure servo posi‐
tion sender - G581- -3-.
– Disconnect and pull off electrical connector -2- on charge
pressure servo position sender - G581- -3-.
– Unscrew bolts -arrows-. Place coolant return line to onenside.
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– Disconnect connector -2- from pressure differential sender -
G505- .
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– Unscrew bolts from intake manifold -arrows-. Place fuel return
line to one side.
108 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove bolts for sealing flange -3- + -4-, remove lifting eye
⇒ Item 10 (page 49) .
– Unscrew union nuts -1- and -3- with socket - T40055- .
– Unscrew bolt -2-.
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– Open clip -arrow- and pull off line from high pressure accu‐
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– Unscrew bolts -arrows-.
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1. Cylinder head 109
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Disconnect connector from fuel pressure regulating valve -
N276- -arrow-.
– Remove cable guide from high pressure accumulator and
place to one side.
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– Detach connector from fuel pressure sender - G247- -B-.
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– Remove high pressure accumulator.
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– Pull vacuum hose -A- off cylinder head cover.
form
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– Remove other vacuum lines from bracket on cylinder head
om
cover.
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– Remove remaining electric cables/wires.
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– Undo and remove bolts -1- to -6- of cylinder head cover.
– Remove cylinder head cover.
110 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unclip cylinder head cover at the locking lugs -arrows- on rear
toothed belt guard.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Renew seal for bolts if damaged.
♦ For clarity of illustration, the camshaft sprocket is not shown.
– Ensure that cylinder head cover is correctly clipped to toothed
belt guard.
– To do this, press toothed belt guard (using a screwdriver if
necessary) against cylinder head cover in area of clips
-arrows- until clips audibly engage in each other.
– Check clearance between hub and toothed belt guard.
– Screw bolts into cylinder head cover in the sequence -1- to
-6-.
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– Tighten bolts in the sequence -1- to -6-.
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diagnostic tester, and perform function “Bleed fuel system”
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⇒ page 268 .
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♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 89 spec
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1.5 Removing and installing injector seals
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1. Cylinder head 111
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Special tools and workshop
equipment required
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♦ Assembly tool - T10208/2-
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♦ Lambda probe open ring spanner set - 3337-
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♦ Tool set - T10055-
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♦ Tool set - T10133-
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♦ Injector remover - T10402-
112 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove noise insulation at injectors.
– Remove only injectors (piezo injectors) whose injector seal is
to be renewed ⇒ page 290 .
– Move affected return lines slightly aside.
Caution
You must therefore proceed very carefully in order to avoid
unnecessary assembly work or further damage.
Maintain cleanliness. No dirt must be allowed to get into the
disconnected fuel return lines or the open connections on the
injectors (piezo injectors).
First remove leaked oil or fuel with workshop equipment.
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– Fit puller - T10055- with injector puller - T10402- d by V -1- and -2- ua
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as shown in illustration. Pull injectors out oupwards
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– Screw oil seal extractor - T40195- forcibly as far as possible
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into seal by hand.
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1. Cylinder head 113
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Pull injector seal upwards by tapping gently using oil seal extrac‐
tor - T40195- , adapter - T101333/2- and slide hammer -
T10133/3- .
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A plastic cylinder head cover is damaged easily during repairs.
Check cylinder head cover for damage.
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– Initially position new injector seal by hand.
– Then carefully push new injector seal in as far as stop using
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assembly tool - T10208/2- .
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1.6 Removing and installing vacuum pump
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The vacuum pump may, under no circumstances, be disman‐
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tled as the vacuum part could otherwise malfunction. This
would result in failure of the brake servo.
Removing
– Remove air filter housing with air mass meter and connecting
pipe ⇒ page 318 .
– Detach vacuum line -2- from vacuum pump -1-.
– Undo and remove bolts of charge air pipe ⇒ page 245 .
– Then push charge air pipe down slightly to gain access to rear
threaded connection of vacuum pump.
– Place cloths under vacuum pump -1-.
114 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew vacuum pump bolts -arrows-.
– Remove vacuum pump from cylinder head.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Ensure that vacuum pump coupling seats properly in cam‐
shaft.
♦ Vacuum pump has been correctly seated in camshaft if it is
lying completely against cylinder head.
♦ The seal must be renewed.
– Install vacuum pump, and tighten securing bolts.
– Connect brake servo vacuum line -2- to vacuum pump -1-.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
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♦ Compression tester - V.A.G 1763- ility
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• Battery voltage at least 12.5 V.
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– Start engine briefly to reduce fuel pressure in fuel rail.
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– Remove glow plugs ⇒ page 369 .
1. Cylinder head 115
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Screw in adapter - V.A.G 1763/8- in each place where glow
plugs were and connect compression tester - V.A.G 1763- .
– Check compression using compression tester - V.A.G 1763- .
Using compression tester ⇒ operating instructions .
– Have a 2nd mechanic operate starter until tester shows no
further pressure increase.
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Assembly is carried out in reverse sequence; note the following:
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116 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Fully enclosing toothed belt guard
⇒ “2.1 Assembly overview - fully enclosing toothed belt guard”,
page 117
⇒ “2.2 Removing and installing upper toothed belt guard (fully
enclosing)”, page 118
⇒ “2.3 Removing and installing lower toothed belt guard (fully en‐
closed)”, page 119
⇒ “2.4 Removing and installing rear toothed belt guard (fully en‐
closing)”, page 120
2.1 Assembly overview - fully enclosing toothed belt guard
1 - Fully enclosing toothed belt
guard
❑ Renew after removal
❑ Rear
❑ Removing and installing
⇒ page 120
2 - Seal
3 - Clips
❑ Qty. 6
4 - Cover
❑ For coolant pump
5 - Bolt
❑ Specified torque
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❑ Specified torque
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⇒ Item 9 (page 125)
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8 - Idler roller
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9 - Coolant pump
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❑ Assembly overview
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⇒ page 206
❑ Removing and installing
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⇒ page 207
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10 - Nut
❑ Renew after removal
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❑ Specified torque
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⇒ Item 16 (page 125)
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11 - Stud
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❑ Specified torque ⇒ Item 22 (page 126)
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13 - Nut
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❑ Specified torque ⇒ Item 24 (page 126)
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❑ Removing and installing ⇒ page 53
2. Fully enclosing toothed belt guard 117
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
15 - Intermediate flange
❑ Removing and installing ⇒ page 119
16 - Fully enclosing toothed belt guard
❑ Bottom
❑ Removing and installing ⇒ page 119
17 - Bolt
❑ Specified torque ⇒ Item 1 (page 50)
18 - Vibration damper
❑ Removing and installing ⇒ page 64
19 - Bolts
❑ Qty. 4
❑ Specified torque ⇒ Item 31 (page 126)
20 - Bolts
❑ Qty. 8
❑ Specified torque ⇒ Item 29 (page 126)
21 - Fully enclosing toothed belt guard
❑ Top
❑ Removing and installing ⇒ page 118
22 - Toothed belt
❑ Removing and installing ⇒ page 127
23 - Camshaft sprocket
❑ Removing and installing ⇒ page 144
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❑ Removing and installing ⇒ page
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25 - Stud ris tee
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26 - Bolt
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❑ Specified torque ⇒ Item 17 (page 126)
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27 - Bolt
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28 - Idler roller
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29 - Bolts
❑ Qty. 2
❑ Specified torque ⇒ Item 34 (page 126)
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30 - Cover
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2.2 Removing and installing upper toothed
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belt guard (fully enclosing)
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118 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench - V.A.G 1331-
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– Remove engine support ⇒ page 37 .
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– Release clips -1-.
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– Unscrew bolts -2-.
spec
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– Carefully pull out fully enclosing toothed belt guard -3- in di‐
t to the co
rection of -arrow-.
Installing
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Install in reverse order of removal, observing the following:
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– To ease assembly, spray silicone lubricant onto fully enclosing
toothed belt guard at front.
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Specified torque
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♦ ⇒ “2.1 Assembly overview - fully enclosing toothed belt guard”,
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Special tools and workshop equipment required
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♦ Torque wrench - V.A.G 1331-
2. Fully enclosing toothed belt guard 119
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove fully enclosed toothed belt guard at top ⇒ page 118 .
– Remove vibration damper ⇒ page 64 .
– Unscrew bolts -2-.
– Remove lower toothed belt guard -1-.
Installing
Install in reverse order of removal, observing the following:
– Insert adapter -1- into lower toothed belt guard -2-.
Specified torque
♦ ⇒ “2.1 Assembly overview - fully enclosing toothed belt guard”,
page 117
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♦ Torque wrench - V.A.G 1331-
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120 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
Note
The toothed belt guard will be destroyed during removal and must
be renewed.
– Remove engine support ⇒ page 37 .
– Remove lower toothed belt guard (fully enclosing)
⇒ page 119 .
– Remove toothed belt ⇒ page 127 .
– Unscrew nut ⇒ Item 10 (page 117) , and remove tensioning
roller ⇒ Item 24 (page 118) .
– Unscrew bolt ⇒ Item 26 (page 118) , and remove idler pulley
⇒ Item 8 (page 117) .
– Unscrew bolt ⇒ Item 27 (page 118) , and remove idler pulley
⇒ Item 28 (page 118) .
– Unscrew nut ⇒ Item 13 (page 117) , and remove idler pulley n AG. Volkswagen A
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– Unscrew bolt ⇒ Item 5 (page 125) , and remove hub
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– Remove coolant pump ⇒ page 207 .
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– Remove insert for coolant pump -4-.
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2. Fully enclosing toothed belt guard 121
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
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– Unscrew bolts -2-.
– Unscrew bolt -3-.
– Remove toothed belt guard -1-. To do this, slightly lever off
toothed belt guard using a screwdriver if necessary.
Installing
122 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
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Install in reverse order of removal, observing the following:
C py
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Note
Prote AG.
♦ The toothed belt guard will be destroyed during removal and must be renewed.
♦ Contact surfaces must be free of dust and grease.
– Clean contact surfaces on cylinder head.
– Apply silicone adhesive sealant - D 174 003 M2- -arrows-
evenly in marked area -1-.
– Fit rear toothed belt guard -1-.
2. Fully enclosing toothed belt guard 123
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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aut ra
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nl
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rrectness of i
• Make sure that rear toothed belt guard is seated correctly in
l purpos
guides in lower area -arrows-.
• Allow silicone adhesive sealant - D 174 003 M2- to cure for
nf
ercia
10 to15 minutes.
orm
m
atio
– Start and tighten bolts for toothed belt guard.
om
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– Add coolant ⇒ page 194 .
thi
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Specified torque
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♦ ⇒ “2.1 Assembly overview - fully enclosing toothed belt guard”,
t.
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page 117 Cop py
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Prote AG.
124 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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lksw not
3 Toothed belt drive Vo gu
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⇒ “3.1 Assembly overview - toothed belt drive”,
aut page 125 ra
c
ss
⇒ “3.2 Removing and installing toothed belt”, page 127
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3.1 Assembly overview - toothed belt drive
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1 - Toothed belt
h re
hole
❑ Mark direction of rota‐
spec
tion before removing es, in part or in w
t to the co
❑ Check for wear
❑ Do not kink
rrectness of i
❑ Removing and installing
⇒ page 127
l purpos
2 - Bolt
nform
ercia
❑ Renew after removal
❑ 20 Nm +45°
m
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com
tion in
3 - Camshaft sprocket
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s
4 - Tensioning pulley
iva
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❑ To remove, remove en‐
um
fo
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g
gine bracket ⇒ page 32
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Cop py
5 - Bolt
t. rig
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❑ 100 Nm
op Vo
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Prote AG.
6 - Hub
❑ Removing and installing
⇒ page 144
7 - Stud
❑ 15 Nm
8 - Idler roller
9 - Bolts
❑ Renew after removal
❑ Qty. 3
❑ 23 Nm
10 - Toothed belt pulley on
high-pressure pump
11 - Bolt
❑ 15 Nm
12 - Idler roller
13 - Toothed belt guard
❑ Rear
14 - Bolt
❑ 20 Nm
15 - Bolt
❑ Renew after removal
❑ 10 Nm
16 - Nut
❑ 20 Nm +45°
3. Toothed belt drive 125
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
17 - Bolt
❑ 50 Nm +90°
18 - Hub
❑ Removing and installing ⇒ page 302
19 - Nut
❑ 95 Nm
20 - Coolant pump
❑ Removing and installing ⇒ page 207
21 - Bolt
❑ 15 Nm
22 - Stud
❑ 15 Nm
23 - Idler roller
24 - Nut
❑ 20 Nm
25 - Crankshaft pulley
26 - Bolt
❑ Renew after removal
❑ Do not additionally oil or grease the threads and shoulder
❑ Turning further can be done in several stages.
❑ 180 Nm +135°
27 - Toothed belt guard
❑ Upper part
28 - Toothed belt guard
AG. Volkswagen AG d
❑ Lower part ksw
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29 - Bolt ised ara
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or
❑ 9 Nm aut
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30 - Belt pulley and vibration damper
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❑ Can only be installed in one position, holes are offset.
an
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❑ Removing and installing ⇒ page 64
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31 - Bolt
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❑ Renew after removal
hole
spec
❑ 10 Nm +90°
es, in part or in w
t to the co
32 - Bolt
❑ Renew after removal
rrectness of i
❑ Observe tightening sequence ⇒ page 34
l purpos
❑ 40 Nm +180°
33 - Engine support
nform
ercia
❑ Removing and installing ⇒ page 32
m
34 - Bolt
com
tion in
❑ 1.5 Nm
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35 - Protective plate
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Cop py
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Prote AG.
126 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Lower toothed belt guard
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3.2 Removing and installing toothed belt
t to the co
rrectness of i
Special tools and workshop
equipment required
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
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fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
♦ 2x diesel injection pump locking pin - 3359-
3. Toothed belt drive 127
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Crankshaft stop - T10050-
♦ Counter-hold tool - T10172- wage
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♦ Angled screwdriver - T10264- d by ua
ran
ir se tee
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♦ Locking tool - T10265-
auth or
ac
ss
♦ Socket XZN 10 - T10385-
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e
nl
pt
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
erm
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
om
ion
c
in t
or
his
ate
do
priv
cum
for
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t.
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Cop py
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co lksw
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Prote AG.
♦ Angled screwdriver - T10409-
128 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Crankshaft stop - T10490-
Note
2 versions of tensioning roller are fitted. They are not interchange‐
able. When performing adjusting measures, check first to see
which tensioning roller is installed.
Observe different directions of rotation during tensioning
Features of tensioning roller A:
♦ Locking tool - T10265- required for installation.
♦ Check that tensioning roller is seated correctly in toothed belt
guard.
♦ Tension toothed belt by turning tensioning roller eccentric
»clockwise«
Features of tensioning roller B:
♦ Locking tool not required.
♦ Tensioning roller is not seated in toothed belt guard.
♦ Tension toothed belt gby rotating
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agen AG
doesroller eccentric
swa
»anticlockwise«
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t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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cum
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t.
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Cop py
ht. rig
rig ht
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co Vo
129
by lksw
cted agen
Prote AG.
3. Toothed belt drive
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Disconnect battery with ignition switched off ⇒ Electrical sys‐ AG. Volkswagen
tem; Rep. gr. 27 ; Disconnecting and reconnecting battery . agen
lksw
AG do
es n
o ot g
yV ua
– Remove noise insulation ⇒ General body repairs,risexterior;
ed
b ran
tee
Rep. gr. 66 ; Body front; Noise insulation . ut
ho
or
a ac
ss
– Remove poly V-belt ⇒ page 48 .
ce
e
nl
pt
du
– Unscrew bolt -1-.
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– Push washer fluid reservoir filler pipe with filler neck -2- to side.
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Note
hole
spec
es, in part or in w
t to the co
♦ Disregard -item 3-.
♦ For reasons of clarity, diagram shows installation position with
fuel filter removed.
rrectness of i
♦ Adjustment work on toothed belts must be performed only on
l purpos
cold engines, as the indicator position on the tensioning ele‐
ment varies depending on the engine temperature.
nform
mercia
at
– Unscrew bolts -arrows-.
om
ion
c
in t
r
– Disconnect electrical connector -1- for coolant shortage indi‐
o
his
te
cator switch - F66- and push coolant expansion tank to side.
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do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Unclip coolant hose bracket -1- by pushing to side.
130 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Loosen bolt -1-.
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– Unscrew bolt -2- and nut -3-. olks es n
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ed ran
– Take hose retainer -4- off fuel filter, place fuel filter h-7-
or aside
is tee
(fuel hoses -5- and -6- remain connected). aut or
ac
ss
ce
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un
pt
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itte
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ab
pe
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Disconnect connector -3- on radiator outlet coolant tempera‐
m
ture sender - G83- .
a
com
tion in
– Unscrew nut -1- and bolt -2-.
r
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thi
s
iva
– Move right coolant pipe along with connected hoses -arrows-
do
r
rp
c
to side.
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fo
en
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t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
– Remove upper timing belt guard by detaching clips -arrows-.
Vehicles with fully enclosing toothed belt guard
– Remove fully enclosed toothed belt guard at top ⇒ page 118 .
Continuation all vehicles
– Remove front right lower wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Remove vibration damper ⇒ page 64 .
3. Toothed belt drive 131
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -arrows-.
– Remove lower toothed belt guard.
Vehicles with fully enclosing toothed belt guard
– Remove lower toothed belt guard (fully enclosing)
⇒ page 119 .
Continuation all vehicles
– Mark direction of rotation of toothed belt.
– Turn crankshaft by bolt for toothed belt sprocket until toothed
belt for camshaft is at “TDC”.
– Fix the hub in place withgelocking
AG. Volkpin
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AG do injection pump
a n
- 3359- . Volksw es n
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Notes au ra
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nl
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-Arrows- can be disregarded.
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itte
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spec
es, in part or in w
t to the co
Version A: lock crankshaft pulley with mark in position
– Lock crankshaft pulley in position with crankshaft stop -
rrectness of i
T10050- .
l purpos
• Marks on toothed belt pulley -2- and crankshaft stop - T10050-
-1- must align.
nf
ercia
• Pin of crankshaft stop - T10050- must engage in drilling in
rm
m
atio
sealing flange.
om
n in
c
• The crankshaft stop - T10050- can be pushed onto the toothed
or
thi
e
belt pulley only from the face side.
t
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For crankshaft pulleys with a mark, it is also possible to use
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crankshaft stop - T10490- .
ht
pyri by
Vo
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by c lksw
– Lock crankshaft pulley in position with crankshaft stop -
cted agen
Prote AG.
T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
holes of toothed belt pulley.
• Locking pin of crankshaft stop - T10490- must engage in hole
in sealing flange.
132 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Version B: lock crankshaft pulley without mark in position
AG. Volkswagen AG d
agen oes
olksw not
Note ed byV gu
ara
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ut
Use only the crankshaft stop -ssT10490- to lock crankshaft pulleys
a ra
c
without a mark in position.
ce
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un
pt
an
d
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– Lock crankshaft pulley in position with crankshaft stop -
rm
ab
T10490- .
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• Pins of crankshaft stop - T10490- must engage in threaded
, is n
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holes of toothed belt pulley.
hole
spec
• Locking pin of crankshaft stop - T10490- must engage in hole
es, in part or in w
t to the co
in sealing flange.
Continuation for all vehicles
rrectness of i
– Loosen bolts -arrows- approx. 90° for camshaft toothed belt
l purpos
pulley.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
by
– Loosen bolts -arrows- by approx. 90° using bit XZN 10 - copy Vo
by lksw
T10385- . cted agen
Prote AG.
Tensioning roller A:
– Loosen securing nut of tensioning roller -1- and turn tensioning
roller eccentric using socket - T10264- counter-clockwise
-arrow- until tensioning roller can be locked with locking pin -
T10265- .
3. Toothed belt drive 133
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Turn eccentric of tensioning roller clockwise -arrow- to stop.
Tighten nut -1- by hand.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
Tensioning roller
ut B:
ho eo
ra
s a c
s
– Loosen securing nut of tensioning roller, rotate eccentric of
ce
le
un
tensioning roller clockwise with socket - T10409- until tension‐
pt
an
d
itte
ing roller is relieved of tension. The tensioner of the tensioning
y li
rm
ab
roller should now be in the 9 o'clock position approximately.
pe
ility
ot
– Re-tighten securing nut hand-tight.
wit
, is n
h re
hole
Continuation for both tensioning rollers
spec
es, in part or in w
t to the co
Caution
Risk of irreparable damage if direction of rotation is reversed rrectness of i
on previously used toothed belt.
l purpos
♦ Before removing toothed belt, mark direction of rotation
with chalk or felt tipped pen for installation purposes.
nform
mercia
a
com
– Remove toothed belt first from idler pulley and then from re‐
tion in
maining toothed belt pulleys.
r
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s
iva
do
Installing
r
rp
cum
fo
en
g
Install in reverse order of removal, observing the following:
n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Note
co Vo
by lksw
cted agen
Prote AG.
♦ The toothed belt may only be adjusted on cold engines, as the
indicator position on the tensioning element varies depending
on the engine temperature.
♦ If the tensioning roller is to be renewed, the engine bracket
must be removed ⇒ page 37 .
Tensioning roller A:
• Tensioning roller must be locked with locking tool - T10265-
and secured to right stop.
• The crankshaft is locked with crankshaft stop - T10050- or
crankshaft stop - T10490- .
134 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Tensioning roller B:
• Set tensioner of tensioning roller to 9 o'clock position.
• Secure tensioning roller with 2 - 4 Nm.
• The crankshaft is locked with crankshaft stop - T10050- or
crankshaft stop - T10490- .
Continuation for both tensioning rollers
Note
If necessary, turn camshaft hub with counterhold - T10172- and
adapters - T10172/4- until camshaft can be secured in position.
To do this, hand-tighten at least one securing bolt -1-.
– Loosen the hand-tightened bolt again.
– Lock camshaft hub with diesel injection pump locking pin -
3359- . To do this, insert locking pin through outer free elon‐
gated hole into hole in cylinder head.
Bolts -arrows- screwed in loosely. wage
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It should just be possible to turn camshaft toothed d by belt pulley ua
ran
without axial movement. ir se tee
tho
u or
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ss ce
le
Note
un
pt
an
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itte
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ab
If necessary, turn hub of high-pressure pump at bolt heads with
pe
ility
screwdriver until it can be secured in position.
ot
wit
, is n
h re
hole
spec
Positioning hub of high-pressure pump
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Toothed belt drive 135
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Lock high-pressure pump hub with diesel injection pump lock‐
ing pin - 3359- . To do this, push locking pin into adjustment
hole outside toothed belt pulley.
Loosely tightened bolts -1-.
It should just be possible to turn high-pressure pump toothed belt
pulley without axial movement.
– Turn camshaft pulley -3- and toothed belt pulley of high-pres‐
sure pump -5- in their elongated holes clockwise to stop.
– Fit toothed belt in sequence described:
1- Crankshaft pulley AG. Volkswagen AG d
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2- Tensioning pulley d by
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3- Camshaft toothed ut
hobelt pulley eo
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4- Coolant pumpstoothed belt pulley
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5- High-pressure pump toothed belt pulley
an
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6- Idler roller
ility
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Tensioning roller A: wit
, is n
h re
hole
– Loosen tensioning roller nut and pull out locking pin - T10265- .
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Note
nform
ercia
Ensure that tensioning roller is seated correctly in rear toothed
belt guard -arrow-.
m
at
om
ion
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in t
or
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ate
do
priv
cum
for
en
ng
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Cop py
t. rig
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by c lksw
cted agen
– Screw eccentric of tensioning roller clockwise carefully using
Prote AG.
angled screwdriver - T10264- . Indicator -2- must be roughly
past the centre of the gap in the base plate (corrects itself dur‐
ing pretensioning).
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.
136 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fit counterhold - T10172- as shown. Press counterhold -
T10172- in -direction of arrow- and keep camshaft pulley in
pretensioning position.
– In this position, first hand-tighten bolts -1- of camshaft pulley
and of toothed belt pulley for high pressure pump and then
tighten to correct torque.
Tensioning roller B:
– Carefully turn eccentric of tensioning roller anticlockwise using
angle driver - T10409- . Indicator -2- must be roughly past the
centre of the gap in the base plate (corrects itself during pre‐
tensioning).
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Markings on tensioning element and tensioning roller -arrow- are
erm
ab
now almost aligned.
ility
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Ensure that securing nut -1- does not turn as well.
h re
ole,
spec
– Hold tensioning roller in this position. Tighten tensioning roller
urposes, in part or in wh
securing nut -1-.
t to the co
rrectness o
cial p
f inform
mer
– Fit counterhold - T10172- as shown. Press counterhold -
atio
m
T10172- in -direction of arrow- and keep camshaft pulley in
o
n
c
pretensioning position.
i
or
n thi
te
sd
a
– In this position, first hand-tighten bolts -1- of camshaft pulley
iv
o
pr
and of toothed belt pulley for high pressure pump and then
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en
ng
tighten to correct torque. yi
t.
Co
Cop py
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co lksw
by
cted agen
Prote AG.
3. Toothed belt drive 137
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– First, tighten securing bolts -arrows- for camshaft pulley by
hand, and then tighten them to specified torque.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
– First, tighten securing bolts of high-pressure pump pulley by
du
an
itte
hand, and then tighten them to specified torque.
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erm
ab
ility
Continuation for both tensioning rollers
ot p
wit
, is n
– Remove diesel injection pump locking pin - 3359- and crank‐
h re
hole
shaft stop - T10050- or crankshaft stop - T10490- .
spec
es, in part or in w
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐
t to the co
gine's direction of rotation until crankshaft is at a position
shortly before “TDC”.
rrectness of i
– Fit crankshaft stop - T10050- or crankshaft stop - T10490- on
crankshaft pulley again.
l purpos
– Turn crankshaft in direction of engine rotation until pin of
crankshaft stop engages in sealing flange whilst turning.
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138 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
G. Volkswagen
During the following checking procedure,
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A AG do
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crankshaft must be secured ind bposition.
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se pump hub again. A mi‐ antee
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♦ Camshaft hub can be locked with locking pin - 3359- .
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♦ Tensioning roller indicator is centred or maximum 5 mm to
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right of base plate notch.
hole
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es, in part or in w
– If the hub of the camshaft can not be locked in position, pull
t to the co
camshaft stop back until the lug exposes the hole.
– Turn crankshaft back to slightly before “TDC” by turning it in
rrectness of i
the opposite direction of engine rotation.
l purpos
– Now turn crankshaft slowly in direction of engine rotation until
camshaft hub can be locked in position.
nf
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– After locking, loosen bolts for toothed belt sprocket of cam‐
or
shaft.
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A - pin of crankshaft stop - T10050- or crankshaft stop - T10490-
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– Turn crankshaft in direction of engine rotation until pin of
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crankshaft stop engages in sealing flange whilst turning.
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– Tighten bolts for camshaft toothed belt pulley. t. Cop py
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– First, turn crankshaft a little in direction opposite to engine's
direction of rotation.
– Turn crankshaft in engine's direction of rotation again until
crankshaft stop pin engages in sealing flange whilst turning.
– Tighten bolts for camshaft toothed belt pulley.
– Remove locking pin - 3359- and crankshaft stop .
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐
gine's direction of rotation until crankshaft is at a position
shortly before “TDC”.
– Repeat measurement.
– If camshaft hub can be secured in position, tighten bolts as
follows:
3. Toothed belt drive 139
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Camshaft pulley: ⇒ Item 2 (page 125) Counterhold with coun‐
terhold - T10172- and adapters - T10172/4- .
♦ High-pressure pump pulley: ⇒ Item 9 (page 125) Counterhold
with counterhold - T10172- and adapters - T10172/8- .
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line white).
Specified torques
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32
♦ ⇒ “1.4 Assembly overview - poly V-belt drive with air condi‐
tioning compressor”, page 52 gen AG
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Prote AG.
140 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 Valve gear
⇒ “4.1 Assembly overview - valve gear”, page 141
⇒ “4.2 Removing and installing camshafts”, page 144
⇒ “4.3 Measuring axial play of camshaft”, page 151
⇒ “4.4 Measuring radial play of camshaft”, page 152
⇒ “4.5 Removing and installing camshaft oil seal”, page 152
⇒ “4.6 Checking hydraulic compensation elements”, page 155
⇒ “4.7 Removing and installing valve stem seals”, page 155
⇒ “4.8 Removing and installing valve stem seals with cylinder
head removed”, page 159
4.1 Assembly overview - valve gear
Caution
Risk of damage to valves and piston crowns after working on
valve gear.
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
Note
AG. Volkswagen AG d
Cylinder heads with cracks between the valve seats omay lksw be used
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by small and no
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Prote AG.
4. Valve gear 141
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Valve
❑ Do not rework. Only lap‐
ping in is permitted.
❑ Mark installation posi‐
tion for re-installation.
❑ Valve dimensions
⇒ page 164
❑ Checking valve guides
⇒ page 163
2 - Cylinder head
❑ See note ⇒ page 87 .
❑ Removing and installing
⇒ page 91
3 - Valve stem seal
❑ Renew with cylinder
head installed
⇒ page 155
❑ Renewing with cylinder AG. Volkswagen AG d
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head removed Volksw
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⇒ page 159 . ed by ara
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4 - Valve springs aut
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5 - Valve spring plate
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6 - Valve cotters
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❑ Removing: With retain‐ spec
urposes, in part or in wh
ing frame installed,
pierce one side of cap
t to the co
with an awl and pry out.
❑ Installing: Drive in with‐
rrectne
out sealant using an ap‐
propriate thrust piece.
s
❑ Drive in depth 1 to 2 mm
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8 - Seal
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❑ Removing and installing ⇒ page 152
atio
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9 - Exhaust camshaft
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❑ Note various versions
t
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❑ Exhaust camshaft with camshaft restraining wheel ⇒ page 143
p
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❑ Exhaust camshaft without camshaft restraining wheel ⇒ page 143 yi
t.
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❑ Measuring axial clearance of camshaft ⇒ page 151
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❑ Removing and installing ⇒ page 144
agen
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10 - Bolt
❑ Sequence when loosening ⇒ page 143 .
❑ Observe tightening sequence ⇒ page 144
❑ 10 Nm
11 - Ladder frame
❑ With integrated camshaft bearings.
❑ Removing and installing ⇒ page 144
12 - Inlet camshaft
❑ Measuring axial clearance of camshaft ⇒ page 151
142 Rep. gr.15 - Cylinder head, valve gear
AG. Volkswagen AG d
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olksw not
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d by 4-cylinder diesel engine (1.6gu l engine,
ara common rail) - Edition 07.2019
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❑ Measuring aradial clearance of camshafts ⇒ page 152
ut ra
c
ss
❑ Removing and installing ⇒ page 144
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13 - Roller rocker fingers itte
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❑ Mark installation position
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❑ Check roller bearing for ease of movement.
hole
spec
❑ Oil contact surface
es, in part or in w
t to the co
❑ Removing and installing ⇒ page 144
14 - Retaining clip
rrectness of i
❑ For hydraulic compensation element.
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15 - Hydraulic compensation element
❑ Checking ⇒ page 155
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❑ Mark installation position
m
❑ Lubricate contact surfaces before installing.
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Exhaust camshaft with camshaft restraining wheel
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Exhaust camshaft without camshaft restraining wheel
Sequence when loosening support frame.
– Unscrew bolts of support frame in sequence -24…1-.
4. Valve gear 143
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Retaining frame - specified torques and installation sequence
– First, tighten bolts of support frame hand-tight in sequence
-1….24-.
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4.2 Removing and installing camshafts
spec
es, in part or in w
t to the co
Special tools and workshop
equipment required
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
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t.
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
♦ Diesel injection pump locking pin - 3359-
144 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Counter-hold tool - T10051-
♦ Puller - T10052-
♦ Camshaft fitting tool - T40094-
♦ Camshaft clamping tool - T40095-
♦ Camshaft fitting tool - T40096-
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
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♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
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com
tion in
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♦ Silicone adhesive sealant ⇒ Electronic parts catalogue (ET‐
ng
t.
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– Remove fuel filter. Prote AG.
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 127 .
– Remove cylinder head cover ⇒ page 106 .
– Unscrew securing bolts -1- of camshaft sprocket.
– Remove camshaft sprocket from hub.
4. Valve gear 145
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Counterhold hub with counterhold - T10051- and loosen hub
securing bolt -1-.
– Unscrew hub securing bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.
– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with a spanner 30 mm whilst doing this.
– Remove hub from taper of camshaft.
– Remove vacuum pump ⇒ page 114 .
Vehicles with fully enclosing toothed belt guard
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The fully enclosing toothed belt guard is bonded,
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– Removing rear toothed belt guard (fully enclosing)
erm
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⇒ page 120 .
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Continuation all vehicles
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spec
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t to the co
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Prote AG.
146 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew retaining frame securing bolts in sequence -24…1-.
– Remove retaining frame.
– Carefully remove camshafts.
Installing
Install in reverse order of removal, observing the following:
Note
Seal parting surface between retaining frame and cylinder head
using silicone adhesive sealant ⇒ Electronic parts catalogue
(ETKA) .
Caution
The camshafts may be installed only with the camshaft fitting wage
n AG. Volkswagen AG do
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tool - T40094- as described below. Otherwise the axial Volksbear‐ ot g
by ua
ings in the retaining frame will be destroyed andris
ethe
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head must be replaced. o tee
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sa
Make sure that no sealant residue gets intos the cylinder head
ce
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or the bearings.
nl
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– Remove sealant residue from cylinder block and retaining
wit
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frame using, for example, a plastic rotary brush.
hole
spec
– Clean sealing surfaces. They must be free of oil and grease.
es, in part or in w
t to the co
– Oil running surfaces of both camshafts.
rrectness of i
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nform
mercia
at
om
ion
c
in t
Prepare camshaft fitting tool - T40094- as follows:
or
his
ate
do
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– Bolt supports -T40094/9- and -T40094/10- (with -T40094/11- )
p
cum
to base plate as shown in illustration. Remove any bolted-on
for
en
g
supports here if necessary.
n
t.
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Prote AG.
4. Valve gear 147
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Place support -T40094/1- in position -F- and support -
T40094/2- in position -A-.
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– Insert inlet camshaft into supports -T40094/1- and -
rm
ab
T40094/2- .
pe
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wit
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– Turn inlet camshaft so that it can be locked in “TDC” position
h re
with locking ruler -arrow 1-.
hole
spec
• The indentation -arrow 2- for the cylinder head bolt must face
es, in part or in w
t to the co
outwards.
rrectness of i
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tion in
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– Insert exhaust camshaft into supports -T40094/9- and -
t. C rig
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T40094/10- . p by
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– Lock exhaust camshaft with cover -T40094/11- . Prote AG.
• The lug -1- of the cover must engage in the slot -2- in the cam‐
shaft.
Vehicles with camshaft tensioning wheel
– Place clamping tool -T40096/1- on teeth of exhaust camshaft
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
• The wider arm must engage in the wider gear half.
– Tighten clamping tool using knurled wheel so that faces of
gear teeth are in alignment.
Continued for all vehicles
– Slide inlet camshaft towards exhaust camshaft until teeth en‐
gage.
148 Rep. gr.15 - Cylinder head, valve gear
gen AG
. Volkswagen AG
does Caddy 2011 ➤
swa
4-cylinder diesel
y Volk engine (1.6 l engine, common
not
gua
rail) - Edition 07.2019
db ran
rise tee
– Place retaining frame -1- on camshafts.
au
tho or
ac
ss
• All camshaft bearings must be seated on the camshafts.
ce
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nl
pt
du
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– Fit camshaft fitting tool - T40095- and fix camshafts in position
itte
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in retaining frame as shown in the illustration.
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es, in part or in w
t to the co
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nform
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at
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ion
c
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or
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ate
– Remove -T40094/11- cover.
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
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Prote AG.
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
2 mm).
– Apply sealant beads (approx. 2 to 3 mm wide), as shown in
diagram, to clean sealing surfaces of cylinder head.
4. Valve gear 149
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
♦ Observe use-by date of sealant.
♦ The sealant beads must not be thicker than specified, other‐
wise excess sealant could enter the camshaft bearings.
– Install new cap ⇒ Item 7 (page 142) flush on cylinder head.
– Remove camshafts from camshaft fitting tool - T40095- to‐
gether with retaining frame and camshaft fitting tool - T40094- .
– Carefully insert camshafts and retaining frame into cylinder
head.
– First, tighten bolts of support frame hand-tight in sequence
-1….24-.
• The retaining frame should make contact with the cylinder
head over the complete surface.
– Tighten retaining frame bolts to final torque in the sequence
-1…24-.
– Remove camshaft fitting tool - T40095- and clamping tool -
T40096/1- .
– Renew camshaft seal ⇒ page 152 .
Caution
Risk of damage to valves and piston crowns after aworking
gen AG on
. Volkswagen AG
does
valve gear. V olksw not
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♦ Because hydraulic compensation elementsris
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have to settle, tee
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engine must not be started for approx.
aut 30 minutes after or
ac
installing camshafts. ss
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pt
♦ Turn the crankshaft carefully at least 2 rotations to ensure
du
an
itte
that none of the valves make contact when the starter is
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operated.
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– Fit hub on camshaft.
spec
es, in part or in w
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– Tighten securing bolt -1- of hub. Use counter-hold tool -
T10051- to do this.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
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ate
do
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150
cted agen
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Push camshaft pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be
on top.
– Insert securing bolts -1- by hand without play to camshaft pul‐
ley.
– Lock hub with locking pin - 3359- .
– Install toothed belt and adjust valve timing ⇒ page 127 .
– Install vacuum pump ⇒ page 114 .
– Install cylinder head cover ⇒ page 106 .
– Install fuel filter.
Specified torques
♦ ⇒ “4.1 Assembly overview - valve gear”, page 141
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 89
4.3 Measuring axial play of camshaft wagen AG. Volkswagen AG doe
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Special tools and workshop equipment required ed by V ara
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♦ Universal dial gauge holder - VW 387- ho eo
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♦ Dial gauge - VAS 6079-
nf
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Prote AG.
4. Valve gear 151
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
– Remove retaining frame ⇒ page 144 .
– Fasten dial gauge - VAS 6079- to cylinder head with universal
dial gauge bracket - VW 387- as shown in the illustration.
– Set dial gauge to “0”.
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
• Specification: 0.048 to 0.118 mm.
• Wear limit: 0.17 mm.
4.4 Measuring radial play of camshaft
Special tools and workshop equipment required
Volkswa
AG. gen AG
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♦ Plastigage Volksw not
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Sequence of operations ho ris nte
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– Remove roller rocker
ss finger ⇒ page 144 . c
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– Remove bearing cap and clean crankshaft journal.
pt
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– Place a length of Plastigage corresponding to the width of the
rm
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bearing on the journal to be measured or into the bearings.
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• The Plastigage must lie in the middle of the bearing.
h re
hole
spec
– Fit retaining frame and tighten without rotating camshafts
es, in part or in w
⇒ page 144 .
– Remove retaining frame again ⇒ page 143 . t to the co
– Compare width of Plastigage with the measurement scale.
rrectness of i
Radial clearance: 0.035 to 0.085 mm.
l purpos
4.5 Removing and installing camshaft oil seal
nform
mercia
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com
tion in
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te o
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by lksw
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Prote AG.
152 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Special tools and workshop
equipment required
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ce
le
♦ Fitting tool - 10-203-
un
pt
an
d
itte
♦ Seal puller - T10443-
y li
erm
ab
ility
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
ot p
wit
is n
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
h re
ole,
spec
♦ Bolt M12 x 1.5 x 75
urposes, in part or in wh
t to the co
Removing
– Removed toothed belt from camshaft and high-pressure pump
rrectne
⇒ page 127 .
– Remove camshaft sprocket and hub ⇒ page 144 .
ss o
Vehicles with fully enclosing toothed belt guard
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
The fully enclosing toothed belt guard is bonded, so it is destroyed
t
sd
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during removal.
i
o
pr
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fo
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t.
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– Removing rear toothed belt guard (fully enclosing)
Co
op py
⇒ page 120 .
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co lksw
by
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Prote AG.
4. Valve gear 153
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Continuation all vehicles
Caution n AG. Volkswagen AG do
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byV ua
If turned too far anti-clockwise, the innerristhrust
ed plate becomes ran
tee
detached from the pressure screw. In uthisth case, the thrust plate
o
or
must be pushed back onto the pressuress
a screw. ac
ce
e
nl
pt
du
an
itte
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– Carefully turn back thrust bolt of oil seal extractor until you feel
erm
ab
slight resistance.
ility
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wit
, is n
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hole
Note
spec
es, in part or in w
t to the co
The clamping sleeves of the oil seal extractor are fitted with grub
screws. However, only one of these grub screws -arrow- effects
clamping. The other is screwed tight.
rrectness of i
l purpos
nform
ercia
– Fit oil seal extractor as shown and screw in grub screw -A- to
m
at
om
clamp it in place.
ion
c
in t
or
– Screw pressure screw -B- in until oil ring has been pulled out.
his
ate
do
riv
Installing
p
cum
for
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Install in reverse order of removal, observing the following:
n
t.
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Note
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Prote AG.
Do not be additionally oil or grease the oil seal sealing lip.
– Remove oil residues from crankshaft journal with a clean cloth.
– Fit guide sleeve - 3240- onto camshaft as shown in illustration.
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
154 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Press in oil seal with press piece of fitting tool - 10-203- and
bolt M12 × 1.5 x 75 as far as stop.
– Install camshaft sprocket and hub ⇒ page 144 .
– Install toothed belt and adjust valve timing ⇒ page 127 .
Specified torques
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
4.6 Checking hydraulic compensation ele‐
ments
Sequence of operations
Note
♦ The hydraulic compensation elements cannot be repaired.
♦ Irregular valve noise during starting is normal.
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to approx. 2500 rpm for 2 minutes. If
necessary, perform road test.
If the hydraulic compensation elements are still noisy, determine
the defective compensation element as follows:
– Remove cylinder head cover ⇒ page 106 .
– Turn crankshaft by the bolt for the toothed belt wheel until cam
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of supporting element wto en Atested
agbe is facing upwards.
oes
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– Press roller rocker
ris
ed
b
finger downwards -arrow- to check
ara clear‐
nte
ance between
ut
ho cam and roller rocker finger. eo
r
sa ac
– If a 0.20s mm feeler gauge can be inserted between cam and
ce
le
roller rocker finger, renew hydraulic compensation element.
un
pt
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d
itte
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rm
ab
pe
ility
ot
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4.7 Removing and installing valve stem
h re
hole
seals
spec
es, in part or in w
t to the co
Special tools and workshop equipment required
♦ Valve stem seal puller - 3364-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
155
Prote AG.
4. Valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Valve stem seal fitting tool - 3365-
♦ Dismantling and assembling device for valve cotters - VAS
5161 A-
Removing AG. Volkswagen AG d
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– Remove all glow isedplugs ⇒ page 369 .
b ara
nte
or eo
h
– Remove camshafts
s aut ⇒ page 144 . ra
c
s
– Remove roller rocker finger ⇒ Item 13 (page 143) . When doing
ce
e
nl
pt
du
so, note the installation position.
an
itte
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ab
– Place guide plate - VAS 5161/23- onto cylinder head.
ility
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– Secure guide plate on intake manifold side with knurled screw
wit
, is n
h re
- VAS 5161/12- and hand-tighten studs with M6 collarless nuts
hole
-1-.
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
– Screw sealing bolts - VAS 5161/10- into the guide plate.
om
n in
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– Screw adapter - VAS 5161/11- hand-tight into the relevant
thi
e
glow plug thread.
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Cop py
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Prote AG.
156 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Insert punch - VAS 5161/3- in the guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
n AG. Volkswagen AG do
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d ran
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– Screw attachment fork - VAS 5161/5- with ratchet piece -
hole
spec
VAS 5161/6- into guide plate .
es, in part or in w
t to the co
– Push spacer ring - VAS 5161/17- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter - VAS 5161/11- to compressed air supply,
rrectness of i
using a standard commercially available union and apply pres‐
l purpos
sure continuously.
• Minimum pressure: 6 bar.
nform
ercia
– Attach pressure fork - VAS 5161/2- to ratchet piece and press
m
assembly cartridge downwards.
at
om
ion
c
– At the same time, turn knurled screw of assembly cartridge
in t
or
his
e
clockwise until tips engage in valve cotters.
at
do
priv
c
– Move knurled screw backwards and forwards slightly. This
um
for
en
causes the valve cotters to be pressed apart and taken into
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the assembly cartridge. t. Cop py
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– Release pressure fork. pyri by
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– Remove assembly cartridge with spacer ring, valve spring Prote AG.
plate and valve spring.
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing
Install in reverse order of removal, observing the following:
4. Valve gear 157
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to
new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– If necessary, use a plastic head hammer to tap lightly on fitting
tool until valve stem oil seal is fitted to stop.
– Remove plastic sleeve.
– Insert valve spring and valve head into cylinder head.
– If valve cotters have been removed from assembly cartridge ,
they need to be put into insertion device - VAS 5161/18- first.
Note
Larger diameter of valve cotters faces upwards.
agen
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– Press assembly cartridge ontoorinsertion
ise
d
device from above ran
tee
and pick up valve cotters. auth or
ac
ss
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un
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– Insert assembly cartridge - VAS 5161/8- into guide plate again.
pe
ility
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– Press pressure fork downwards and pull knurled screw up‐
h re
wards, turning it clockwise and anticlockwise. This action will
hole
spec
install the valve cotters.
es, in part or in w
t to the co
– Reduce pressure on pressure fork whilst pulling on knurled
screw.
rrectness of i
– Install camshafts ⇒ page 144 .
– Install glow plugs ⇒ page 369 .
l purpos
nform
ercia
Note
m
a
com
tio
♦ Engine is not to be rotated for approx. 30 minutes after instal‐
n in
ling camshafts. The hydraulic compensation elements must
r
te o
thi
settle (otherwise valves will strike pistons).
s
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rp
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♦ After working on the valve gear, turn the engine carefully at
fo
en
g
least 2 rotations to ensure that none of the valves make con‐
n
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Specified torques by c lksw
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♦ ⇒ “4.1 Assembly overview - valve gear”, page 141
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 89
158 Rep. gr.15 - Cylinder head, valve gear
AG. Volkswagen AG d
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Volksw not
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Caddy 2011 ➤
y
rise
d b
4-cylinder dieselaengine
ran
tee
(1.6 l engine, common rail) - Edition 07.2019
tho
u or
a ac
4.8 ss Removing and installing valve stem
ce
le
seals with cylinder head removed
un
pt
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d
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ab
Special tools and workshop equipment required
ility
ot p
♦ Valve stem seal puller - 3364-
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
♦ Valve stem seal fitting tool - 3365-
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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♦ Dismantling and assembling device for valve cotters - VAS
5161 A-
♦ Engine and gearbox support - VAS 6095A-
4. Valve gear 159
AG. Volkswagen AG d
agen oes
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Caddy 2011 ➤ d by
V gu
ara
e nte
4-cylinder dieselthoengine (1.6 l engine, common rail) - Edition
ris
07.2019
eo
au ra
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♦ Cylinder head tensioning device - VAS 6419-
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f
Removing
inform
mer
– Remove camshafts ⇒ page 144 .
atio
om
– Mark allocation of roller rocker fingers and hydraulic compen‐
n
c
i
or
n
sation elements for reinstallation.
thi
te
sd
va
– Remove roller rocker fingers together with hydraulic compen‐
i
o
pr
cum
r
sation elements and place down on a clean surface.
fo
en
ng
t.
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– Insert cylinder head tensioning device - VAS 6419- into engine Cop py
t. rig
and gearbox support - VAS 6095A- . opyri
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– Tension cylinder head on cylinder head tensioning device as
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shown in illustration.
AG.
– Connect cylinder head tensioning device to compressed air.
– Use lever -arrow- to slide air cushion under combustion cham‐
ber from which valve stem seal is to be removed.
– Allow compressed air to flow into air cushion until it lies against
valve spring plate.
– Place guide plate -VAS 5161/23- onto cylinder head.
– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
160 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
AG. Volkswagen AG d
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nl
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– Screw toothed piece -VAS 5161/6- with hooking fork -
h re
VAS 5161/5- into guide plate.
hole
spec
es, in part or in w
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
t to the co
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
rrectness of i
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
l purpos
clockwise until tips engage in valve cotters.
nf
ercia
– Move knurled screw back and forth to press apart valve cotters
or
and capture them in assembly cartridge.
m
m
atio
m
– Release pressure fork.
o
n in
or c
thi
e
– Remove assembly cartridge together with spacer.
t
sd
iva
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– Remove valve spring and valve spring plate.
o
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f
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t.
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op
– Pull off valve stem seal using valve stem seal puller - 3364- . C py
t. rig
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pyri by
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by
Caution cted agen
Prote AG.
Risk of damage when valve stem seals are being installed!
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to
new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
4. Valve gear 161
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– If valve cotters have been removed from assembly cartridge ,
they need to be put into insertion device - VAS 5161/18- first.
• Larger diameter of valve cotters faces upwards.
– Insert valve spring and valve spring plate.
– Press assembly cartridge onto valve cotter insertion device
from above and pick up valve cotters.
– Insert assembly cartridge - VAS 5161/8- into guide plate -
VAS 5161/23- again.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilstepulling
n AG. Volon
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agen AG
screw. olks
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not
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– Repeat procedure on each ovalve.
ris
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Installing s au ra
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Install in reverse order of removal, observing the following:
un
pt
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itte
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– Ensure that all roller rocker fingers contact valve stem ends
erm
ab
correctly and are clipped into relevant hydraulic compensation
ility
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elements.
wit
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– Install camshafts ⇒ page 144 .
ole,
spec
urposes, in part or in wh
Specified torques t to the co
♦ ⇒ “4.1 Assembly overview - valve gear”, page 141
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 89
rrectne
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.
162 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
5 Inlet and exhaust valves
⇒ “5.1 Reworking valve seats”, page 163
⇒ “5.2 Checking valve guides”, page 163
n AG. Volkswagen AG do
⇒ “5.3 Checking valves”, pageol164
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⇒ “5.4 Valve dimensions”,
ris page 164
ed ran
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5.1 Reworking valve seats ss au ac
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nl
pt
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Note
erm
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ility
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Do not rework valve seats due to the very small tolerances.
wit
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hole
spec
5.2 Checking valve guides
es, in part or in w
t to the co
Special tools and workshop equipment required
♦ Universal dial gauge holder - VW 387-
rrectness of i
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mercia
at
om
ion
c
in t
or
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ate
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for
en
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♦ Dial gauge - VAS 6079-
co lksw
by
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Prote AG.
5. Inlet and exhaust valves 163
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
Note
♦ If the valve is to be renewed as part of a repair, use a new
valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Insert valve into valve guide.
• The end of the valve stem must be flush with the guide.
– Determine rock.
AG. Volkswagen AG d
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• Wear limit: 1.0 mm. Volksw
oes
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d
– If the wear limit is exceeded,
orise repeat the measurement with nte
eo
new valves. auth
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– Renew cylinder head if wear limit is still exceeded.
ce
le
un
pt
an
d
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rm
ab
Note
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ility
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wit
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Valve guides cannot be exchanged.
h re
hole
spec
es, in part or in w
5.3 Checking valves t to the co
– Check for scoring on valve stems and valve seat surfaces.
rrectness of i
– Exchange valve if significant scoring can be seen.
l purpos
5.4 Valve dimensions
nform
mercia
Note
com
tion in
r
te o
thi
Never rework the inlet and exhaust valves. Only lapping-in is per‐
s
iva
mitted.
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cum
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t.
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Dimension Inlet valve Outlet valve
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∅a mm 26.50 … 26.70 24.4 … 24.60
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b mm 99.30 99.10
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Diameter mm 5.968 … 5.982 5.958 … 5.972
c
d ∠° 45 45
164 Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 165
⇒ “1.2 Removing and installing sump”, page 167
⇒ “1.3 Removing and installing oil pump”, page 171
⇒ “1.4 Engine oil:”, page 173
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 173
⇒ “1.6 Measuring oil consumption”, page 174
1.1 Assembly overview - sump/oil pump
1 - Bolt
❑ 15 Nm
2 - Sealing flange
❑ With seal
❑ Must seat on dowel
sleeves. gen AG
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❑ Insert with silicone seal‐ y Volk not
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ant ⇒ Electronic parts risedb ara
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catalogue (ETKA) . ut
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a
❑ Do not additionally oil orss c
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grease the oil seal seal‐
un
ing lip. pt
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d
itte
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rm
❑ Before installing, re‐ ab
pe
move oil residue from ility
ot
wit
crankshaft journal using
, is n
h re
a clean cloth.
hole
spec
❑ Renewing crankshaft oil
es, in part or in w
seal on belt pulley end
t to the co
⇒ page 66 .
❑ Removing and installing
rrectness of i
⇒ page 53
l purpos
3 - Toothed belt for oil pump
❑ Check for damage and
wear.
nform
ercia
❑ Renew if necessary.
m
a
com
tion in
Note
r
te o
thi
s
iva
do
♦ Belts which have been in use
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rp
cum
longer can sag.
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ng
t.
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♦ This is not a fault and does not Cop py
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necessarily mean belt needs re‐ yri
gh by
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placing.
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4 - Bolt
❑ 10 Nm
5 - Oil dipstick
❑ The oil level must not be above the max. mark!
❑ Markings ⇒ page 173 .
1. Sump, oil pump 165
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
6 - Guide tube
7 - Clip
8 - Dowel sleeves
❑ Renew after removal
9 - O-ring
❑ Renew after removal
10 - Bolt
❑ 10 Nm
11 - Oil pump with pressed-on toothed belt pulley
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
If toothed belt or oil pump have to be removed:
♦ Check oil pump for free movement en AG. Volkswagen AG
ag does
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♦ It should be possible to turn toothed belt sprocket easily witho1t gfinger.
by ua d ran
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♦ Replace if difficult to turn.
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12 - Suction line s
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e
nl
pt
❑ Clean strainer if soiled
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an
itte
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13 - Baffle plate
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14 - Bolt
wit
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❑ 15 Nm
hole
spec
15 - Sump
es, in part or in w
❑ Clean sealing surface before fitting. t to the co
❑ Install with silicone sealant ⇒ Electronic parts catalogue (ETKA) .
rrectness of i
❑ Removing and installing ⇒ page 167
l purpos
16 - Bolt
❑ Specified torque and tightening sequence ⇒ page 167
nform
ercia
17 - Spreader clip
m
at
❑ Only vehicles with cover for oil sump
om
ion
c
❑ large
in t
or
his
ate
18 - Spreader clip
do
priv
cum
or
❑ Only vehicles with cover for oil sump
f
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ng
t.
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❑ small
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19 - Cover for oil sump
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❑ Not fitted in all vehicles Prote
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agen
20 - Bolt
❑ 10 Nm
21 - Oil level and oil temperature sender - G266-
❑ 3-pin
❑ Removing and installing ⇒ page 173
22 - Seal
❑ Renew after removal
23 - Oil level and oil temperature sender - G266- wiring harness
❑ Connector, black
24 - Oil drain plug
❑ Renew after removal
166 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
❑ 30 Nm
25 - Seal
❑ Renew after removal
26 - Bolt
❑ 15 Nm
27 - Bolt
❑ Insert without sealant.
❑ 27 Nm
28 - Oil spray jet
❑ Removing and installing ⇒ page 85
Sump - specified torque and tightening sequence
– Tighten bolts in 3 stages:
Stage Bolts Specified torque
1) -1 … 20- In diagonal sequence to 5 Nm
2) -Arrows- 40 Nm
3) -1 … 20- Diagonally in stages; final torque
13 Nm
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1.2 Removing and installing sump s a c
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Special tools and workshop equipment required
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♦ T-bar and socket, 10 mm - 3185-
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1. Sump, oil pump 167
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4-cylinder diesel engine (1.6thor l engine, common rail) - Edition 07.2019 eo
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♦ Hexagon key - T10058-
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Removing
nform
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– Drain engine oil ⇒ Maintenance ; Booklet 39 .
m
at
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– Open clips -1- and -2- and remove connecting hose.
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– Unscrew bolts -arrows-.
– Free off coolant hose -3-.
– Release hose clip -2-.
– Disconnect electrical connector -1- on charge pressure sender
- G31- and remove right air pipe.
– Screw bolt out -arrow- and push coolant circulation pump 2 -
V178- to the side.
168 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove bolts -arrows- of charge air pipe.
AG. Volkswagen AG d
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urposes, in part or in wh
– Disconnect electrical connector -arrow- on oil level and oil
temperature sender - G266- .
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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– Remove noise insulation -1- for sump. To do this, open fas‐
fo
en
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teners -arrows-.
t.
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– Remove connecting bolts for sump and gearbox.
– Slacken bolts -1 … 20- in diagonal sequence and remove.
– Release sump carefully from adhesive.
– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant remaining on crankcase with flat scraper.
1. Sump, oil pump 169
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Installing
Install in reverse order of removal, observing the following:
WARNING
AG. Volkswagen AG d
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Risk of eye injury!
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♦ Wear safetyhorisgoggles.
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♦ Coversopen
s a
parts of engine. c
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nl
pt
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an
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– Remove sealant residue from bottom section of sump -1- us‐
erm
ab
ing a rotating plastic brush, for example.
ility
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• Make sure to not damage the surface coating of the bottom
h re
section of sump.
hole
spec
es, in part or in w
• Sealing surfaces must be free of grease and oil.
t to the co
Use sealant as per ⇒ Electronic parts catalogue (ETKA) .
rrectness of i
l purpos
Note
Observe use-by date of sealant.
nform
mercia
at
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
om
ion
3 mm).
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Prote AG.
170 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Apply bead of sealant onto clean sealing surface of sump as
illustrated.
• Thickness of sealant bead: 2…3 mm.
Note
♦ Do not apply sealant bead thicker than specified.
♦ Take particular care when applying sealant bead -arrows- in
area of rear sealing flange.
♦ The sump must be installed within 5 minutes after sealant is
applied.
♦ When installing sump with engine removed, ensure that sump
is flush with crankcase at flywheel end.
♦ Let sealing compound dry for approx. 30 minutes after instal‐
ling oil sump. Only then fill with engine oil.
– Place oil sump in position and slightly tighten the sump--to-
gearbox connecting swa
gbolts
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that sump isbyflush
Volk against intermediate plate ot and
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flange. rised ara
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– Install
s a coolant circulation pump 2 - V178- .
u ac
s
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– Install air pipes ⇒ page 245 .
un
pt
an
d
itte
– Installing intake hoses with screw-type clips ⇒ page 246 .
y li
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ab
ility
– Install noise insulation ⇒ General body repairs, exterior; Rep.
ot p
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gr. 66 ; Body - front; Noise insulation .
is n
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ole,
– Replenish engine oil and check oil level ⇒ Maintenance ;
spec
urposes, in part or in wh
Booklet 39 .
t to the co
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 165
rrectne
1.3 Removing and installing oil pump
ss o
cial p
Removing
inform
mer
– Remove sump ⇒ page 167 .
atio
om
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1. Sump, oil pump 171
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– When oil pump is to be renewed, unscrew bolts -4- and remove
oil intake pipe -3-.
– Unscrew bolts -arrows- and remove baffle -2-.
– Detach oil pump -1- from toothed belt and remove pump.
– Check oil pump for ease of movement, turn toothed belt pulley
with one finger for this.
Note
♦ If oil pump does not move easily, it must be renewed.
♦ A damaged toothed belt must be renewed.
♦ The toothed belt can sag after long use, this is not a fault.
– Check toothed belt for oil pump.
Installing
Install in reverse order of removal, observing the following:
– Renew O-ring.
– Insert new dowel sleevesgewhen
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-arrows- for centring
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– Fit oil pump owith
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teetight‐
en along awith
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h baffle. or
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– Install sump ⇒ page 167 .
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– Replenish engine oil and check oil level ⇒ page 173 .
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Specified torques
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♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 165
h re
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
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172 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.4 Engine oil:
Note
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
ing. This is normal and regulates itself automatically. No engine
oil needs to be drained.
1 - Min. mark
2 - Max. mark
a - Oil level in min. mark area: replenish engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Oil level in max. mark area: Do not replenish engine oil!
d - The oil level may be in this area as a result of particular driving
conditions.
Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter! Markings
Oil capacities
With oil filter change: 4.3 l
Without oil filter change: 4.0 l
1.5 Removing and lkswinstalling
agen oil
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oil
temperature sender - G266-
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Removing utho or
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– Drain engine oil.
ce
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un
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– Disconnect electrical connector -arrow- on oil level and oil
itte
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rm
temperature sender - G266- .
ab
pe
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spec
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– If fitted, remove noise insulation -1- for sump. To do this, loos‐
en retaining elements -arrows-.
nform
mercia
a
com
tion in
r
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thi
s
iva
do
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Prote AG.
1. Sump, oil pump 173
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -2-.
– Remove oil level and oil temperature sender - G266- -1-.
Installing
Install in reverse order of removal, observing the following:
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet 39 .
Specified torques
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 165
1.6 Measuring oil consumption
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
Sequence of operations
– Apply handbrake.
– Manual gearbox: gear lever in neutral.
– Automatic gearbox: move selector lever to position “N”.
AG. Volkswagen AG d
– Connect ⇒ Vehicle diagnostic tester.
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– Switch on ignition. edb ara
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– Carry out program “oilau consumption measurement” using ra
c
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⇒ Vehicle diagnostic tester.
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174 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine
AG . (1.6
Volkswl engine,
agenA common rail) - Edition 07.2019
n G do
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Volks ot g
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2 Engine oil cooler thoris tee
or
s au ac
⇒ “2.1 Removing and installing engine
s oil cooler”, page 175
ce
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un
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2.1 Removing and installing engine oil cool‐
an
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ab
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Special tools and workshop equipment required is n
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♦ Used oil collector and extractor - VAS 6622A-
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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♦ Drip tray for workshop hoist - VAS 6208-
um
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♦ Spring-type clip pliers - VAS 6362-
2. Engine oil cooler 175
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Open air intake cover. To do this, carefully release the catches
-arrows-.
– Unscrew bolts -arrows- for air intake -1- and take connecting
hose -2- out of guide.
– Press in locking lugs -1- and -3- and pull connecting hose -4-
off air filter housing -2-.
– Remove air filter housing ⇒ page 318 .
– Remove radiator cowl ⇒ page 218 . AG. Volkswagen AG d
agen oes
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– Drain coolant ⇒ page 194 . d by Vo gu
ara
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ility
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– In addition to draining coolant from engine, pull coolant hose
h re
from oil filter holder -arrow-.
hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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Prote AG.
176 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove oil filter element.
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un
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– Unscrew bolts -arrows-.
an
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– Remove engine oil cooler from housing.
pe
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es, in part or in w
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nform
ercia
Installing
m
Install in reverse order of removal, observing the following:
com
tion in
r
te o
thi
s
iva
Note
do
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rp
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fo
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♦ Renew gaskets, seals and O-rings.
n
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♦ Hose unions and air intake pipes and hoses must be free of
t. rig
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oil and grease before installation.
p by
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– Insert new seals ⇒ Item 11 (page 180) into oil free lugs
-arrow- on oil filter bracket.
– Carefully slide engine oil cooler onto centring pins.
– Press on oil cooler until it is flush -1- with end of centring pins.
– Start new bolts, and screw them in until heads make contact.
2. Engine oil cooler 177
Caddy 2011 ➤ agen
AG. Volkswagen AG d
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4-cylinder diesel engine (1.6
by
V l engine, common rail) - Edition
ol not
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ara
ed nte
oris
– Tighten bolts -arrows- alternately
au
th in diagonal sequence in 3 e or
ac
steps. ss
ce
le
un
pt
– Install oil filter element, replenish engine oil and check oil level.
an
d
itte
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– Replenish coolant in cooling system, change coolant if engine
rm
ab
pe
ility
oil cooler has been renewed ⇒ page 194 .
ot
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Specified torques
h re
hole
spec
♦ ⇒ “3.1 Assembly overview - oil filter housing with engine oil
es, in part or in w
cooler”, page 179
t to the co
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
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t.
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Prote AG.
178 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 Oil filter, oil pressure switch
⇒ “3.1 Assembly overview - oil filter housing with engine oil cool‐
er”, page 179
⇒ “3.2 Removing and installing oil filter housing”, page 180
⇒ “3.3 Removing and installing oil pressure switch F1 ”,
page 183
⇒ “3.4 Checking oil pressure switch”, page 185
⇒ “3.5 Checking oil pressure”, page 186
3.1 Assembly overview - oil filter housing
with engine oil cooler
Caution
Seals ⇒ Item 11 (page 180) and ⇒ Item 14 (page 180) must
not be lubricated with oil. The coolant seals would otherwise
swell up.
1 - O-ring
❑ Renew after removal
2 - Cap
❑ 25 Nm
3 - O-ring
❑ Renew after removal
4 - O-ring agen
AG. Volkswagen AG d
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❑ Renew after removal
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5 - Oil filter element
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❑ Observe s general notes
s
ce
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on the lubrication sys‐
un
pt
tem ⇒ page 5
an
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❑ Observe change inter‐
ab
pe
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vals ⇒ Maintenance ;
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Booklet 39 ; Proce‐
, is n
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dures .
hole
spec
6 - Guide tube
es, in part or in w
t to the co
❑ Renew O-ring after
each removal
rrectness of i
7 - Bolt
❑ 10 Nm
l purpos
8 - Spreader clip
nform
ercia
9 - Engine oil cooler
m
❑ Ensure clearance to ad‐
com
tio
jacent components
n in
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❑ Renew coolant after re‐
s
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placing
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❑ Observe general notes
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coolant hoses ⇒ page 193 Prote
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agen
3. Oil filter, oil pressure switch 179
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
. Volkswagen AG
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❑ Checking engine oil cooler for leaks ⇒ page 193 Volkswa not
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❑ Removing and installing ⇒ page 180 ris
ed
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10 - Bolt s au ra
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❑ Initial specified torque: 5 Nm
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❑ 11 Nm
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11 - Rubber seals
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❑ May not be lubricated with oil
t to the co
12 - Bolt
❑ Renew after removal
rrectne
❑ First, start upper left and lower right bolts.
❑ Tightening sequence ⇒ page 180
ss
❑ 14 Nm +180°
o
cial p
f inform
13 - Oil filter bracket
mer
atio
❑ Ensure clearance to adjacent components
om
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❑ With integrated oil non-return
i
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❑ Removing and installing ⇒ page 180
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Tightening sequence for oil filter bracket
3.2 Removing and installing oil filter housing
Special tools and workshop equipment required
180 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Release lever - 80 - 200-
AG. Volkswagen AG d
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cted AG.
agen
3. Oil filter, oil pressure switch 181
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove air filter housing ⇒ page 318 .
– Remove radiator cowl ⇒ page 218 .
– Drain coolant ⇒ page 194 .
– Remove oil filter element.
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– Loosen hose clamps -1- and -2- and remove air hose.
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t to the co
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– Unscrew bolts -arrows-.
m
a
com
ti
– Free off coolant hose -3-.
on in
r
te o
thi
– Release hose clip -2-.
s
iva
do
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– Disconnect electrical connection -1- on charge pressure send‐
rp
cum
fo
er - G31- / intake air temperature sensor - G42- and remove
en
ng
t.
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right charge air pipe.
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Prote AG.
182 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull out oil dipstick slightly, unscrew bolt -1-.
– Press off clip -2- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side.
– Place drip tray for workshop hoist - VAS 6208- under coupling
point.
AG. Volkswagen AG d
agen oes
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h
aut ra
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– Remove coolant hose -4-, loosening hose clip -3- to do so.
nl
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– Place used oil collection and extraction unit - VAS 6622A- un‐
y li
erm
ab
der engine.
ility
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– Unscrew bolts -2- and remove oil filter bracket together with
, is n
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engine oil cooler.
hole
Installing spec
es, in part or in w
t to the co
Install in reverse order of removal, observing the following:
rrectness of i
Note
l purpos
♦ Renew gaskets, seals and O-rings.
nform
ercia
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
m
at
om
ion
c
in t
r
– Install dipstick guide tube ⇒ page 179 .
o
his
ate
do
riv
– Install charge air pipe ⇒ page 245 .
p
cum
for
en
g
– Installing intake hoses with screw-type clips ⇒ page 246 .
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t.
yi Co
op py
– Install air filter housing ⇒ page 319 .
t. C rig
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pyri by
Vo
o
– Install radiator cowl ⇒ page 218 . by c lksw
cted agen
Prote AG.
– Install oil filter element, replenish engine oil and check oil level
⇒ Maintenance ; Booklet 39 .
– Replenish coolant in cooling system, change coolant if engine
oil cooler has been renewed ⇒ page 194 .
Specified torques
♦ ⇒ “3.1 Assembly overview - oil filter housing with engine oil
cooler”, page 179
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
3.3 Removing and installing oil pressure
switch - F1-
Special tools and workshop equipment required
3. Oil filter, oil pressure switch 183
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench - V.A.G 1331-
♦ Hose clamp pliers - VAS 6340-
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lkswage es n
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Removing ss
ce
e
nl
pt
– Remove hose -1- for crankcase breather system. To do this,
du
an
itte
press the release buttons.
y li
erm
ab
ility
– Move clear vacuum hoses -arrows-.
ot p
wit
, is n
– Release hose clips -3- and pull air hose off air filter housing.
h re
hole
spec
– Unscrew bolt -2-, swing intake hose with intake connection to
es, in part or in w
rear and pull off of turbocharger.
t to the co
rrectness of i
l purpos
nf
ercia
– Unscrew bolts -2- and -3-, remove engine lifting eyes -1-.
orm
m
atio
– Separate electrical connector -arrow-.
om
n in
c
– Remove oil pressure switch - F1- .
or
thi
te
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Installing
o
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f
Install in reverse order of removal, observing the following:
en
ng
t.
yi Co
op py
– Install vacuum line to exhaust gas recirculation cooler. t. C rig
gh ht
yri by
– Install intake connection.
cop Vo
by lksw
cted agen
Prote AG.
184 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– When fitting intake connecting pipe to turbocharger, ensure
that intake connecting pipe is correctly seated on stud of tur‐
bocharger. -arrow-.
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
3.4 Checking oil pressure switch
Special tools and workshop
equipment required
AG. Volkswagen AG d
agen oes
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ed
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un
pt
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d
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
sd
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r
fo
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.
♦ Oil pressure tester - V.A.G 1342-
♦ Voltage tester - V.A.G 1527 B-
♦ Adapter set - V.A.G 1594 C-
3. Oil filter, oil pressure switch 185
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Checking oil pressure switch - F1-
Test conditions
• Oil level OK, checking ⇒ page 173
• Engine oil temperature at least 80°C (radiator fan must have
run once)
Test sequence
Note
Functional check and repair of the optical and acoustic oil pres‐ swa
gen AG
. Volkswagen AG
does
sure warning: ⇒ Current flow diagrams, Electrical fault finding and by V olk not
gu
Fitting locations ris
ed ara
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– Remove oil pressure switch - F1- ⇒ page 183 . ss
ce
le
un
pt
– Screw oil pressure switch - F1- -2- into oil pressure tester -
an
d
itte
V.A.G 1342- .
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rm
ab
pe
ility
– Remove oil pressure switch - F1- -2- and screw into oil pres‐
ot
wit
sure tester - V.A.G 1342- .
, is n
h re
hole
– Connect brown line -1- of oil pressure tester to earth (–).
spec
es, in part or in w
– Connect voltage tester - V.A.G 1527B- with auxiliary cables
t to the co
from auxiliary measuring set - V.A.G 1594C- to oil pressure
switch - F1- and battery positive (+).
rrectness of i
• LED should not light up.
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If the LED lights up:
– Replace oil pressure switch - F1-
nform
ercia
If LED does not light up:
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tion in
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Note
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Observe oil pressure tester and LED while starting, as switching
fo
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point of oil pressure switch - F1- may already be exceeded when
n
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starting. C py
ht. rig
rig ht
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co Vo
– Start engine and slowly increase engine speed.
by lksw
cted agen
Prote AG.
• From 0.30 to 0.60 bar upwards, the LED must light up, other‐
wise renew oil pressure switch - F1- ⇒ page 183 .
Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
3.5 Checking oil pressure
Special tools and workshop equipment required
186 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Oil pressure tester - V.A.G 1342-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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or eo
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spec
Test conditions
es, in part or in w
t to the co
• Oil level OK, checking ⇒ page 173 .
• Engine oil temperature at least 80°C (radiator fan must have
rrectness of i
run once)
l purpos
Test sequence
– Remove oil pressure switch - F1- ⇒ page 183 .
nform
ercia
– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
m
a
sure switch - F1- .
com
tion in
– Screw an old oil pressure switch into hole on oil pressure tester
r
te o
thi
- V.A.G 1342- to seal hole.
s
iva
do
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– Start engine.
um
fo
en
ng
t.
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• Oil pressure at idling speed: at least 0.6 bar
Co
Cop py
t. rig
gh
• Minimum oil pressure at 2,000 rpm: at least 1.0 bar
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
3. Oil filter, oil pressure switch 187
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 Oil circuit
⇒ “4.1 Assembly overview - oil circuit”, page 188
⇒ “4.2 Removing and installing oil supply line”, page 189
4.1 Assembly overview - oil circuit
1 - Bolts
❑ Qty. 2
❑ 20 Nm
2 - Oil supply line
❑ Removing and installing
⇒ page 189
3 - Oil return line
❑ Renew seal after each
removal
4 - Bolt
❑ 22 Nm AG. Volkswagen AG d
agen oes
lksw not
5 - Nuts d by
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❑ Renew after removal horis
eo
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❑ Qty. 2 ss a c ce
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❑ 22 Nm
nl
pt
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6 - Connection pipe to exhaust
erm
ab
gas recirculation cooler
ility
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❑ Renew seals after each
wit
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removal
hole
spec
7 - Bolt
es, in part or in w
t to the co
❑ 10 Nm
8 - Support
rrectness of i
❑ for turbocharger
l purpos
9 - Banjo bolt
❑ Renew after removal
nform
ercia
❑ Renew seals after each
removal
m
at
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io
❑ For banjo bolts ⇒ Elec‐
n
c
in t
r
tronic parts catalogue
o
his
te
(ETKA) , observe the
a
do
riv
following:
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❑ Banjo bolt ► 31.01.2012: 60 Nm
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❑ Banjo bolt 01.02.2012►: 100 Nm
C py
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10 - Banjo bolt
op Vo
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❑ Renew after removal Prote AG.
❑ Renew seals after each removal
❑ 30 Nm
11 - Bolts
❑ Qty. 2
❑ 9 Nm
188 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4.2 Removing and installing oil supply line
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331- .
♦ Tool insert, AF 17 mm - T10395-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
♦ Used oil collector and textractor
ho
r - VAS 6622A- eo
au ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
nform
ercia
terior; Rep. gr. 66 ; Noise insulation; Removing and installing
noise insulation .
m
at
om
io
– Unscrew bolts -arrows-.
n
c
in t
or
his
e
– Remove heat shield for right drive shaft.
at
do
priv
– Unbolt right drive shaft from gearbox, and tie it up on the side
um
for
en
g
⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft;
n
t.
yi Co
Removing and installing drive shaft . t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
4. Oil circuit 189
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Disconnect electrical connector -2- at pressure differential
sender - G505- .
– Unscrew bolt -3-.
– Unscrew bolt -4-.
– Remove pressure differential sender - G505- from bracket
-arrow-.
– Remove clamp -1- between particulate filter and turbocharger.
n AG. Volkswagen AG do
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ss
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nl
pt
du
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itte
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
– Unscrew bolt -1-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
190 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew nuts -2-.
Note
Do not bend de-coupling element in front exhaust pipe by more
than 10°.
– Place particulate filter -1- aside.
– Unscrew nuts -2-.
– Unscrew bolts -3-.
– Remove connecting pipe -1- for exhaust gas recirculation
cooler.
– Remove exhaust gas temperature sender 1 - G235-
⇒ page 351 .
– Unscrew bolt -2- of turbocharger support -1-.
– Collect leaking oil with used oil collection and extraction
wage
n AGunit
. Volk-swagen AG
does
VAS 6622A- . yV
olks not
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nl
pt
du
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ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
atio
om
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or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
191
by lksw
cted agen
Prote 4. Oil circuit
AG.
Caddy 2011 ➤ agen
AG. Volkswagen AG d
oes
ksw not
4-cylinder diesel engine (1.6 l engine, common
by rail)
Vol
- Edition 07.2019 gu
a
ed ran
oris tee
– Loosen banjo bolt -4- of oil return line -1- on acrankcase.
ut
h or
ac
ss
– Loosen banjo bolt -5- of oil supply line -2- on crankcase.
ce
le
un
pt
an
d
– Unscrew bolt -3-.
itte
y li
erm
ab
– Unscrew bolts -6-.
ility
ot p
wit
is n
– Unscrew banjo bolts -4- and -5-.
h re
ole,
spec
– Detach turbocharger support.
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
a
Installing
iv
o
pr
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Install in reverse order of removal, observing the following:
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ng
t.
yi Co
op
• To ensures stress-free installation, the following work steps
C py
t. rig
gh
must be carried out as described.
ht
pyri by
Vo
co lksw
by
– Fit turbocharger support with combined flange to crankcase
cted agen
Prote AG.
and turbocharger.
– Start banjo bolt -4- and bolts -6- for combined flange.
– Tighten banjo bolt -4- and bolts -6- alternately.
– Tighten banjo bolt -5- of oil supply line -2- on crankcase.
– Tighten bolt -3- of retainer.
– Tighten bolt -2- of turbocharger support -1-.
Note
♦ Renew gaskets, seals, O-rings and self-locking nuts ⇒ Elec‐
tronic Parts Catalogue (ETKA) .
♦ Renew seal and clamp for particulate ⇒ Electronic Parts Cata‐
logue (ETKA) .
♦ If the particulate filter or pressure differential sender - G505-
are renewed, the pressure differential sender - G505- must be
adapted using the ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “4.1 Assembly overview - oil circuit”, page 188
♦ ⇒ “2.2 Assembly overview - particulate filter”, page 344
192 Rep. gr.17 - Lubrication
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
19 – Cooling n AG. Volkswagen AG do
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1 Cooling system/coolant o
ir se
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ran
tee
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u
⇒ “1.1 Connection diagram - scoolant
s a hoses”, page 193 ac
ce
e
⇒ “1.2 Draining and adding coolant”, page 194
nl
pt
du
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itte
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⇒ “1.3 Checking cooling system for leaks”, page 202
erm
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ility
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⇒ “1.4 Checking engine oil cooler for leaks”, page 204
wit
, is n
h re
1.1 Connection diagram - coolant hoses
hole
spec
es, in part or in w
t to the co
1 - Expansion tank
2 - Radiator/cooler
rrectness of i
❑ For exhaust gas recircu‐
l purpos
lation
3 - Heat exchanger for heater
nf
ercia
❑ With quick-release cou‐
orm
pling
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4 - Cylinder head/cylinder
or c
block
thi
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5 - Engine oil cooler
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6 - Coolant circulation pump -
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7 - Upper coolant hose cop Vo
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cted agen
❑ With quick-release cou‐ Prote AG.
pling
8 - Radiator/cooler
❑ Removing and installing
⇒ page 219
9 - Lower coolant hose
❑ With quick-release cou‐
pling
10 - Coolant pump/thermostat
❑ Removing and installing
⇒ page 207
11 - Supplementary heater
❑ If fitted
1. Cooling system/coolant 193
n AG. Volkswagen AG do
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Caddy 2011 ➤ yV
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b ua
4-cylinder diesel engine (1.6 l engine, common
ir se
d rail) - Edition 07.2019 ran
tee
tho
u or
a ac
1.2 Draining and adding coolant ss
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le
un
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an
⇒ “1.2.1 Draining and adding coolant”, page 194
d
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erm
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⇒ “1.2.2 Charging the cooling system in the case of emergency”,
ility
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page 200
wit
is n
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1.2.1 Draining and adding coolant
ole,
spec
urposes, in part or in wh
t to the co
Special tools and workshop
equipment required
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Hose clamp pliers - VAS 6340-
♦ Coolant system charge unit - VAS 6096-
♦ Adapter for cooling system tester - V.A.G 1274/8-
194 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Draining
WARNING
Danger of scalding by steam and hot coolant.
On a warm engine, the cooling system is under high pressure.
Cover filler cap on expansion tank with a cloth and open care‐
fully to release pressure.
en AG. V
olkswagen AG
ag does
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– Open filler
horis
cap on coolant expansion tank. nte
eo
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– Remove
ss noise insulation ⇒ General body repairs, exterior; c
ce
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Rep. gr. 66 ; Body front; Noise insulation .
nl
pt
du
an
itte
– Place drip tray - VAS 6208- beneath engine.
y li
erm
ab
ility
ot p
– Remove air intake hose. To do this, loosen hose clips -1- and
wit
, is n
-2-.
h re
hole
spec
es, in part or in w
t to the co
Note
To prevent ingress of coolant, seal connection on charge air cool‐
rrectness of i
er using a clean plug from engine bung set - VAS 6122- .
l purpos
nf
ercia
orm
m
atio
om
n in
c
– Pull coolant hose -arrow- off coolant circulation pump 2 -
or
thi
e
V178- .
t
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f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Disconnect lower coolant hose from radiator. To do this, lift up
retaining clip -arrow- and drain coolant.
1. Cooling system/coolant 195
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen
n AG do
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– In addition to draining
ed
by coolant from
V
engine, pull coolant ua hose
ran
off engine oil cooler
horis -arrow-. tee
aut or
ac
ss
ce
e
Note
nl
pt
du
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itte
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erm
Please observe disposal instructions!
ab
ility
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wit
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Filling
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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o
m
f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
196 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, always use only distilled
water when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the motor.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise G. Volkswagen AG d
the boiling point of the coolant. For this reason, the cooling lkswagen A oes
not
system must be filled all-year-round with coolant additives.
db
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♦ Because of its high boiling point, the coolant improves
ut
ho engine or
reliability under heavy loads, particularly in countries
ss
a with trop‐ ac
ical climates.
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un
pt
an
d
♦ The refractometer - T10007A- must be used to determine the
itte
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current anti-freeze value.
rm
ab
pe
ility
ot
♦ Frost protection must be guaranteed down to -25°C as a min‐
wit
, is n
imum and, in countries with arctic conditions, down to approx.
h re
hole
-36°C. Increasing the frost protection is permissible only if cli‐
spec
matic conditions require stronger frost protection. It may, how‐
es, in part or in w
t to the co
ever, be increased only to a maximum of -48°C. Otherwise,
the cooling effect will be impaired.
♦ Do not reduce the coolant concentration by adding water even
rrectness of i
in warmer seasons and in warmer countries. Frost protection
must be guaranteed down to at least -25°C.
l purpos
♦ Read off anti-freeze figures for respective replenished coolant
additives.
nform
ercia
♦ The temperature read off the refractometer - T10007A- corre‐
m
a
com
ti
sponds the »ice flocculation point«. Flakes of ice may start
on in
forming in the coolant below this temperature.
r
te o
thi
s
iva
♦ Never reuse old coolant.
do
r
rp
cum
fo
♦ Use only a water/coolant additive mixture as a slip agent for
en
ng
t.
yi
coolant hoses.
Co
Cop py
t. rig
gh ht
yri by
Coolant mixture ratio
op Vo
by c lksw
cted agen
Prote AG.
• Coolant additive (40 %) and distilled water (60 %) for frost
protection to -25 °C
• Coolant additive (50%) and distilled water (50%) for frost pro‐
tection to -36 °C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
– Reconnect coolant hoses, and secure them with clamps.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Body - front; Noise insulation .
1. Cooling system/coolant 197
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio.
Note
The quantity may vary depending on the equipment level.
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank -1-. agen
AG. Volkswagen AG d
oes
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V
– Mount cooling system charge unit - VAS 6096- on adapter ed by - gu
ara
V.A.G 1274/8- . thoris nte
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au ac
– Feed vent hose -2- into a small container -3-. ss
ce
e
nl
pt
du
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itte
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Note
erm
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ility
ot p
Exhaust air takes a slight quantity of coolant along with it; this
wit
, is n
h re
should be collected.
hole
spec
es, in part or in w
– Close valves -A- and -B- (turn lever transverse to direction of
t to the co
flow to do this).
– Connect hose -4- to compressed air.
rrectness of i
• Pressure: 6 to 10 bar.
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198 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Open valve -B-; turn lever in direction of flow to do this.
• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move into green area.
– In addition, open valve -A- briefly by turning lever in direction
of flow until expansion tank hose of cooling system charge unit
- VAS 6096- fills with coolant.
– Close valve -A- again.
– Leave valve -B- open for a further 2 minutes.
• Vacuum continues to be generated in the cooling system by
the suction jet pump; the needle of gauge must remain in green
range.
– Close valve -B-.
• The needle on the gauge should stop in the green zone. The
vacuum level in the cooling system is then sufficient for sub‐
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ If vacuum drops, cooling system must be checked for leaks.
– Pull off compressed air hose.
– Open valve -A-.
• The vacuum in the cooling system causes coolant to be ex‐
tracted from coolant expansion tank of cooling system charge
unit - VAS 6096- and the cooling system to be filled.
– Remove cooling system charge unit - VAS 6096- from coolant
expansion tank. AG. Volkswagen gen AG do
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– Fill coolant up tobymax.
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– If fitted, sswitch
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– Start engine and maintain engine speed at approx. 2000 rpm
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– Then run engine at idling speed until radiator fan cuts in.
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rrectness of i
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fully to release pressure.
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– Check coolant level and top up as needed.
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• The coolant level must be at the max. marking when the en‐
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• When the engine is cold, the coolant level must be between
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1. Cooling system/coolant
Caddy 2011 ➤ n AG. Volkswagen AG
4-cylinder diesel engine (1.6 l engine, commonl wage - Edition 07.2019does n
ksrail)
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1.2.2 Charging the cooling system in the case
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system charge unit - VAS 6096- .
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♦ Charging in the case of an emergency is only permissible to
keep the vehicle mobile and does not replace the proper
rrectness of i
charging procedure according to the repair manual.
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♦ After an emergency charging, the vehicle should be brought
to a workshop as soon as possible where the cooling system
should be filled properly in accordance with the repair manual.
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Sequence of operations
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Danger of scalding by steam and hot coolant.
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– Open filler cap on coolant expansion tank.
200 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
♦ Use only distilled water for mixing coolant additives. The use
of distilled water ensures optimum protection against corro‐
sion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, always use only distilled
water when mixing coolant for topping up or renewing coolant.
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♦ Use only coolant additives which conform with theVo⇒lksElec‐
wa does
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tronic parts catalogue (ETKA) . Other coolant eadditives
db
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reduce corrosion protection substantially. The
horis resulting dam‐ nte
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age could lead to loss of coolant and subsequent
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damage to the motor. s
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♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
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rosion damage as well as scaling. Such additives also raise
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reliability under heavy loads, particularly in countries with trop‐
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♦ The refractometer - T10007A- must be used to determine the
current anti-freeze value.
rrectne
♦ Frost protection must be guaranteed down to -25°C as a min‐
imum and, in countries with arctic conditions, down to approx.
ss
-36°C. Increasing the frost protection is permissible only if cli‐
o
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matic conditions require stronger frost protection. It may, how‐
inform
ever, be increased only to a maximum of -48°C. Otherwise,
mer
the cooling effect will be impaired.
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♦ Do not reduce the coolant concentration by adding water even
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in warmer seasons and in warmer countries. Frost protection
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must be guaranteed down to at least -25°C.
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♦ Read off anti-freeze figures for respective replenished coolant
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additives.
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forming in the coolant below this temperature. Prote AG.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Coolant mixture ratio
• Coolant additive (40 %) and distilled water (60 %) for frost
protection to -25 °C
• Coolant additive (50%) and distilled water (50%) for frost pro‐
tection to -36 °C
• Coolant additive ⇒ Electronic parts catalogue (ETKA)
– Fill a suitable container with pre-mixed coolant observing the
correct mixing ratio.
– Fill the cooling system via the coolant expansion tank up to
max. marking.
– Close coolant expansion tank.
– If fitted, switch off air conditioning system.
1. Cooling system/coolant 201
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Start engine and maintain engine speed at approx. 2000 rpm
for about 3 minutes.
– Then run engine at idling speed until radiator fan cuts in.
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Danger ofssscalding by steam and hot coolant.
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– Check coolant level and top up as needed.
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• The coolant level must be at the max. marking when the en‐
gine is warm.
• When the engine is cold, the coolant level must be between
rrectne
min. and max. marking.
s
1.3 Checking cooling system for leaks
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Special tools and workshop equipment required
form
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♦ Cooling system tester - V.A.G 1274 B-
om
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♦ Adapter for cooling system tester - V.A.G 1274/8-
202 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Adapter for cooling system tester - V.A.G 1274/9-
Sequence of operations
• Engine at operating temperature.
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♦ On a warm engine, the cooling system is under high pres‐ s
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♦ Cover filler cap on expansion tank with a cloth and open
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carefully to release pressure.
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– Open filler cap on expansion tank.
spec
urposes, in part or in wh
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– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/8- to coolant expansion tank.
rrectne
– Build up pressure of approx. 1.0 bar using hand pump of cool‐
ing system tester.
ss
– If this pressure is not maintained, locate and rectify leaks.
o
cial p
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Prote AG.
1. Cooling system/coolant 203
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Checking pressure relief valve in filler cap:
– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- to filler cap -1-.
– Build up pressure using hand pump of cooling system tester.
• The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
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1.4 Checking engine oil cooler for leaks olks ot g
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♦ Refractometer - T10007 A-
♦ Hose clamps to 25 mm - 3094-
♦ Cooling system tester - V.A.G 1274-
♦ Adapter for cooling system tester - V.A.G 1274/8-
204 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Spring-type clip pliers - VAS 5024 A- discontinued, use hose
clip pliers - VAS 6340-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Not illustrated
♦ Expansion tank
♦ Cap
♦ Commercially available plug
♦ Commercially available hose
Condition:
• Engine cold
Test sequence
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
– Drain coolant ⇒ page 194 .
– Loosen hose clip on engine oil cooler with hose clip pliers
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– Remove engine oil cooler with housing ⇒oripage
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♦ Collect escaping coolant with drip tray - VAS 6208- .
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♦ Collect leaking engine oil with a cleaning cloth, if necessary.
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Checking when removed
es, in part or in w
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– Clamp casing with the old gasket onto a suitable, flat clean
surface with the help of a bar clamp -4-.
rrectness of i
– Attach plug -2- to venting connection of expansion tank -1-.
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– Attach coolant hose -3- to engine oil cooler -5- and to expan‐
sion tank -1-.
nform
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– Fill expansion tank up to max. mark.
m
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
com
tion in
system tester - V.A.G 1274/8- on coolant expansion tank -1-.
r
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– Generate about 1.6 bar pressure using hand pump of tester.
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– Observe pressure drop on pressure gauge. A pressure drop
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within 10 minutes is not permitted.
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– Renew engine oil cooler ⇒ page 179 .
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Install in reverse order of removal, observing the following:
– Renew housing seal.
– Check coolant level and, if necessary, replenish ⇒ page 194 .
– Check engine oil level and, if necessary, replenish
⇒ page 173 .
1. Cooling system/coolant 205
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Coolant pump, regulation of cooling
system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 206
⇒ “2.2 Assembly overview - coolant pump and thermostat, from
week 22/2011”, page 207
⇒ “2.3 Removing and installing coolant pump”, page 207
⇒ “2.4 Removing and installing 4/2-way valve with thermostat”,
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⇒ “2.5 Removing and installing coolant temperatureissender
ed
b G62 ran
”, page 214 uthor tee
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⇒ “2.6 Removing and installing radiator outlet scoolant tempera‐
ce
e
ture sender G83 ”, page 215
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2.1 Assembly overview - coolant pump, thermostat
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1 - Coolant pump
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❑ Removing and installing
es, in part or in w
⇒ page 207
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2 - Bolt
❑ 15 Nm
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3 - O-ring
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❑ Renew after removal
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4 - O-ring
❑ Renew after removal
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5 - 4/2-way valve with thermo‐
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stat
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ate
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❑ The thermostat is loca‐
p
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ted within the 4/2-way
f
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valve and cannot be re‐
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new individually.
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❑ Removing and installing p by
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6 - Bolt
❑ 15 Nm
206 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2 Assembly overview - coolant pump and thermostat, from week 22/2011
1 - Bolt
❑ 15 Nm
2 - 4/2-way valve upper part
❑ Removing and installing
4/2-way valve
⇒ page 208 .
3 - Thermostat
❑ Starts to open at 92°C
❑ Completely open at
107°C
4 - O-ring agen
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❑ Renew after removald by V gu
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5 - 4/2-way valve loweruthpart
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❑ Removing ands installing
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4/2-way valve
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⇒ page 208 .
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6 - Bolt
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❑ Renew after removal
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8 - O-ring
❑ Renew after removal
9 - Coolant pump rrectness of i
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❑ Removing and installing
⇒ page 207
nf
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10 - Bolt
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❑ 15 Nm
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2.3 Removing and installing coolant pump Cop py
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Special tools and workshop equipment required
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♦ Torque wrench - V.A.G 1331-
2. Coolant pump, regulation of cooling system 207
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove toothed belt ⇒ page 127 .
– Drain coolant ⇒ page 194 .
– If fitted, detach coolant pump cover ⇒ Item 4 (page 117) .
– Unscrew bolts -2-.
– Remove coolant pump -1-.
Installing
Install in reverse order of removal, observing the following:
Note
♦ Check contact surfaces for coolant pump on crankcase for dirt.
Clean them with sandpaper as necessary.
♦ Renew gaskets and seals. n AG. Volkswagen AG do
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♦ The coolant pump plug faces downwards.
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– Add coolant ⇒ page 194s a.u or
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Specified torques
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♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
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urposes, in part or in wh
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32 rrectne
2.4 Removing and installing 4/2-way valve with thermostat
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208 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Special tools and workshop
equipment required
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♦ 10 mm jointed spanner - 3185-
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♦ Refractometer - T10007 A-
hole
spec
♦ Hexagon key - T10058-
es, in part or in w
t to the co
♦ Torque wrench - V.A.G 1331/-
♦ Drip tray for workshop hoist - VAS 6208-
rrectness of i
♦ Hose clamp pliers - VAS 6340-
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Note
nform
mercia
at
The thermostat is located within the 4/2-way valve and cannot be
om
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renew individually.
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2. Coolant pump, regulation of cooling system 209
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove air filter housing with air mass meter and connecting
pipe ⇒ page 319 .
– Drain coolant ⇒ page 194 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐
ing and installing alternator .
– Guide alternator with extreme caution past radiator to prevent
damaging it.
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– Pull wiring harness clip -arrow- out of bracket.
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– Lay wiring harnesses -arrows- and connector -1- on bracket
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Prote AG.
210 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -2-, -2- and -arrows-.
– Free electrical lines and hoses on left air pipe from fittings us‐
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– Loosen hose clips -1- and pull coolant hoses off.
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Note
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-Items 2, 3, 4- can be disregarded.
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– Remove electrical connector -1- for Hall sender - G40- from
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Note
-Items 2 and 3- can be disregarded.
– Pull out coolant pipe from connection -C- of 4/2-way valve but
leave in installation position.
2. Coolant pump, regulation of cooling system 211
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -arrows-.
– Free off coolant hose -3-.
Instructions for hose connections ⇒ page 246
– Open clamp -2-.
– Disconnect electrical connection -1- on charge pressure send‐
er - G31- / intake air temperature sensor - G42- and remove
right charge air pipe.
– Unscrew bolt -1-.
– Press off clip -2- using removal lever - 80 - 200- .
– Pull out oil dipstick guide tube from cylinder block upwards and
push to one side.
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– Remove throttle valve module - GX3- ⇒ page 316 .
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212 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull coolant hoses off connections -A, B and D-.
– Unscrew bolts -3- for 4/2-way valve -2-.
– Pull out valve from cylinder block.
Installing
Install in reverse order of removal, observing the following:
– Clean and smoothen sealing surface for O-ring.
– Moisten new O-ring -1- with coolant.
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– Thread 4/2-way valve in past ancillary bracket in direction of
h re
hole
oil filter module.
spec
es, in part or in w
t to the co
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l purpos
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a
com
tion in
r
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thi
– Insert connection -2- of 4/2-way valve with O-ring -1- into cyl‐
s
iva
do
inder block with slight rotary motions.
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Prote AG.
2. Coolant pump, regulation of cooling system 213
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Thread coolant pipe into connection -C- of 4/2-way valve.
– Tighten bolts -3- using T-bar and socket, 10 mm - 3185- .
– Install charge air pipe ⇒ page 245 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing alternator .
– Install throttle valve module - GX3- ⇒ page 316 .
– Add coolant ⇒ page 194 .
Specified torques AG. Volkswagen AG d
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♦ ⇒ “2.1 Assembly doverview
by
Vo
- coolant pump, thermostat”, gu
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♦ ⇒ “2.2 Assembly
ss a overview - coolant pump and thermostat, c
from week 22/2011”, page 207
ce
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2.5 Removing and installing coolant temper‐
erm
ab
ility
ot p
ature sender - G62-
wit
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Special tools and workshop equipment required
spec
urposes, in part or in wh
♦ Release lever - 80 - 200-
t to the co
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cial p
f inform
mer
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c
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– Briefly open filler cap for coolant expansion tank in order to by c lksw
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reduce pressure in cooling system. Prote AG.
– Remove air filter housing ⇒ page 319 .
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
214 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -2-, -5- and -arrows-.
– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
Instructions for hose connections ⇒ page 246
– Loosen hose clip -3- and remove left air pipe.
Note
Disregard -items 1, 2, 4, 5-.
– Pull connector -4- off coolant temperature sender - G62- .
Note
Place a cloth under connecting piece to absorb escaping coolant.
– Pull off retaining clip -3- and pull coolant temperature sender
- G62- out of screw connection.
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-Items 1 and 2- can be disregarded. s auth
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pt
du
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Install in reverse order of removal, observing the following:
erm
ab
ility
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Note
hole
spec
es, in part or in w
♦ Renew O-ring.
t to the co
♦ Insert new coolant temperature sender - G62- immediately in‐
to union to avoid loss of coolant.
– Check coolant level and top up if necessary ⇒ page 194 . rrectness of i
l purpos
2.6 Removing and installing radiator outlet
nform
ercia
coolant temperature sender - G83-
m
at
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c
Removing
in t
or
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ate
• Engine cold.
do
priv
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– Briefly open filler cap for coolant expansion tank in order to
f
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reduce pressure in cooling system.
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co lksw
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Prote AG.
2. Coolant pump, regulation of cooling system 215
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Loosen bolt -1-.
– Unscrew bolt -2- and nut -3-.
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
– Pull connector -2- off radiator outlet coolant temperature send‐
er - G83- .
Note
Place a cloth underneath to catch escaping coolant.
– Pull off retaining clip -1- and pull coolant temperature sender
at radiator outlet - G83- out of screw connection of coolantwagen AG. Volkswagen AG doe
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Install in reverse order of removal, observing the
ss following:
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nl
pt
du
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itte
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ab
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♦ Renew O-ring.
, is n
h re
hole
♦ Insert new coolant temperature sender - G83- immediately in‐
spec
to coolant pipe at radiator outlet to avoid loss of coolant.
es, in part or in w
t to the co
– Check coolant level and top up if necessary ⇒ page 194 .
rrectness of i
l purpos
nf
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orm
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or c
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Cop py
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Prote AG.
216 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 Radiator, radiator fan
. Volkswagen AG
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⇒ “3.1 AssemblyVooverview
lksw
a - radiator/radiator fan”,
not page 217
y gu
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⇒ “3.2 Removing
or
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ran
tradiator
e fan
V7 andaradiator
uth fan on right of radiator V35 ”, page 218e or a
ss c
⇒ “3.3 Removing and installing radiator”, page 219
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3.1 Assembly overview - radiator/radiator fan
itte
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1 - Radiator/cooler
h re
hole
❑ After renewing, renew
spec
entire coolant.
es, in part or in w
t to the co
❑ Removing and installing
⇒ page 219
rrectness of i
2 - O-ring
❑ Renew if damaged
l purpos
3 - Upper coolant hose
nform
ercia
❑ Connection diagram for
coolant hoses
m
a
⇒ page 193
com
tion in
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4 - Cap
thi
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❑ Check using cooling
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system tester -
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V.A.G 1274- and adapt‐
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⇒ page 202
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5 - Connector
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6 - Bolt
5 Nm
7 - Expansion tank
❑ With coolant tempera‐
ture display sender -
G32- .
❑ Check cooling system
for leaks with cooling
system tester -
V.A.G 1274- and adapt‐
er - V.A.G 1274/8-
⇒ page 202
8 - Lower coolant hose
❑ Connection diagram for
coolant hoses ⇒ page 193
9 - Nut
❑ 5 Nm
10 - Bolt
❑ 5 Nm
11 - Additional fan for radiator
12 - Main fan for radiator
13 - Connector
14 - Radiator cowl
❑ Removing and installing ⇒ page 218
3. Radiator, radiator fan 217
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Connecting coolant hose with plug-in connector
– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Push coolant hose into connection -1- until it audibly engages.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back.
3.2 Removing and installing cowling togeth‐
er with radiator fan - V7- and radiator fan
on right of radiator - V35-
Removing
– Remove air filter housing with connecting pipe ⇒ page 319 .
– If present, remove noise insulation ⇒ General body repairs,
exterior; Rep. gr. 66 ; Body, front; Noise insulation .
– Remove upper bolts -arrows- of air cowling.
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nl
pt
du
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erm
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ility
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wit
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– Pull back securing lever -1- onto stop
hole
spec
– Push down securing lever -2- and pull off connector
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
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ion
c
in t
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ate
do
priv
cum
for
en
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t.
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Cop py
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by c lksw
cted agen
Prote AG.
218 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew lower bolts -arrows-.
– Turn air cowling together with radiator fans anti-clockwise a
little and remove downwards.
Vehicles with 2 radiator fans
– Disconnect electrical connector -1- and free electrical wiring.
– Unscrew bolts -arrows- and remove radiator fans.
Vehicles with one radiator fan
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– Unscrew bolts -arrows- and remove radiator fan.
an
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itte
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Installing
erm
ab
ility
ot p
Install in reverse order of removal, observing the following:
wit
is n
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Specified torques
ole,
spec
urposes, in part or in wh
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 217
t to the co
rrectness o
cial p
f in
3.3 Removing and installing radiator
form
mer
atio
om
n
c
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Cop py
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Prote AG.
3. Radiator, radiator fan 219
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Special tools and workshop
equipment required
AG. Volkswagen AG d
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pt
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spec
es, in part or in w
♦ Refractometer - T10007 A- t to the co
♦ Torque wrench - V.A.G 1783-
rrectness of i
♦ Drip tray for workshop hoist - VAS 6208-
l purpos
Removing
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
nform
ercia
terior; Rep. gr. 66 ; Noise insulation .
m
– Remove air filter housing with connecting pipe ⇒ page 319 .
at
om
ion
c
in t
– Removing and installing air cowling together with radiator fan
or
his
e
- V7- and right radiator fan - V35- ⇒ page 218 .
at
do
priv
– Drain coolant ⇒ page 194 .
um
for
en
ng
t.
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– Pull coolant hoses off radiator.
Co
Cop py
ht. rig
– Remove radiator securing bolts ⇒ Item 10 (page 217) and re‐
rig ht
py by
Vo
move radiator.
co lksw
by
cted agen
Prote AG.
Installing
Install in reverse order of removal, observing the following:
– Add coolant ⇒ page 194 .
220 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Specified torques
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 217
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ate
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pyri by
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co lksw
by
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Prote AG.
3. Radiator, radiator fan 221
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 Coolant pipes
⇒ “4.1 Assembly overview - coolant pipes”, page 222
⇒ “4.2 Removing and installing lower coolant pipe”, page 223
⇒ “4.3 Removing and installing upper coolant pipe”, page 227
⇒ “4.4 Removing and installing left coolant pipe”, page 228
⇒ “4.5 Removing and installing right coolant pipe”, page 230
4.1 Assembly overview - coolant pipes
1 - Grommet
❑ Not sold separately
2 - Sleeve
❑ Not sold separately
3 - Bolt AG. Volkswagen AG d
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❑ 3 Nm Volksw
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4 - Bolt orise nte
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❑ 40 Nm ss au ra
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5 - Bracket
un
pt
an
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❑ For coolant circulation
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ab
pump 2 - V178-
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ility
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6 - Coolant pipe
wit
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❑ Front h re
hole
spec
es, in part or in w
7 - O-ring
t to the co
❑ Renew after removal
8 - Coolant pipe
rrectness of i
❑ Right
l purpos
9 - O-ring
❑ Renew after removal
nform
ercia
10 - Radiator outlet coolant
m
temperature sender - G83-
com
tion in
r
11 - Retaining clip
te o
thi
s
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12 - Bolt
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❑ 8 Nm
en
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13 - Nut
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❑ 8 Nm p by
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14 - Bolt Prote AG.
❑ 8 Nm
15 - Coolant line
16 - Bolt
❑ 8 Nm
17 - Seal
❑ Renew after removal
18 - Union
19 - Bolt
❑ 8 Nm
222 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
20 - Retaining clip
21 - Radiator outlet coolant - G62-
22 - O-ring
❑ Renew after removal
23 - Centre hex stud
❑ 8 Nm
24 - Bolt
❑ 8 Nm
25 - Coolant pipe
❑ Left
26 - Bolt
AG. Volkswagen AG d
❑ 8 Nm agen oes
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27 - Bolt rised
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❑ 40 Nm aut ra
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ss
28 - Bolt
ce
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du
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❑ 13 Nm
itte
y li
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ab
29 - Coolant circulation pump 2 - V178-
ility
ot p
wit
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h re
hole
spec
4.2 Removing and installing lower coolant
es, in part or in w
t to the co
pipe
Special tools and workshop equipment required
rrectness of i
♦ Release lever - 80 - 200-
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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rig ht
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cted agen
♦ Hose clamps to 25 mm - 3094-
Prote AG.
4. Coolant pipes 223
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Spring-type clip pliers - VAS 6362-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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un
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an
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itte
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ab
ility
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Removing
wit
is n
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– Drain coolant ⇒ page 194 .
ole,
spec
urposes, in part or in wh
– Remove air filter housing ⇒ page 319 .
t to the co
– Disconnect earth wire -arrow- from battery with ignition switch‐
ed off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
reconnecting battery .
rrectne
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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op
– Remove battery tray. Unscrew bolts -arrows-. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
224 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove crankcase breather hose -1- from cylinder head cov‐
er. To do this, press release buttons.
– Expose vacuum hoses -arrows- at air pipe.
– Unscrew bolt -2-.
– Swing air pipe together with intake connection towards rear
and pull them off the turbocharger.
– Unclip wiring harness from bracket -arrow-.
Vehicles with dual clutch gearbox:
AG. Volkswagen AG d
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ab
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ot
wit
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– Clamp off coolant hoses using hose clamps to 25 mm - 3094-
hole
spec
and remove from gear oil cooler. To do this, loosen hose clips
es, in part or in w
-arrows-. t to the co
Continued for all vehicles:
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Lay wiring harnesses -arrows- and electrical connector -1- on
do
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rp
bracket to side.
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fo
en
ng
t.
yi
Instructions for hose connections ⇒ page 246
Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. Coolant pipes 225
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove air intake hose. To do this, loosen hose clips -1- and
-2-.
– Unscrew bolts -2-, -5- and -arrows-.
– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
– Loosen hose clip -3- and remove left air pipe.
Note
-Items 1 and 4- can be disregarded.
AG. Volkswagen AG d
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– Loosen hose clips -1- and pull off coolant hoses. d byV
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-Items 2, 3, 4- can be disregarded.
itte
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ab
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ility
ot
wit
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h re
hole
spec
es, in part or in w
t to the co
– Remove electrical connector -1- for Hall sender - G40- from
rrectness of i
bracket.
l purpos
– Remove bracket from front coolant pipe.
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
226 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Loosen hose clips -2- and -3-, and pull off coolant hoses.
G . Volkswage
– Unscrew bolts -arrows-ksw
aand
gen Apull front coolant
n AG d
opipe
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l
way valve. by
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Installing tho tee
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Install in reverse
s order of removal, observing the following:
ce
le
un
pt
an
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itte
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rm
Note
ab
pe
ility
ot
wit
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♦ Renew gaskets, seals and O-rings.
h re
hole
♦ Hose unions and air intake pipes and hoses must be free of
spec
oil and grease before installation.
es, in part or in w
t to the co
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic parts catalogue (ETKA) .
rrectness of i
– Clean or smoothen sealing surface for O-ring.
l purpos
– Moisten O-ring with coolant and slide onto front coolant pipe.
nform
ercia
– Push front coolant pipe into 4/2-way valve.
m
a
com
tio
– When fitting intake connecting pipe to turbocharger, ensure
n in
r
that intake connecting pipe is correctly seated on stud of tur‐
te o
thi
bocharger. -arrow-.
s
iva
do
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rp
cum
– Add coolant ⇒ page 194 .
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ng
t.
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Specified torques t. Cop py
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♦ ⇒ “4.1 Assembly overview - coolant pipes”, page 222 yri
p by
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by c lksw
cted
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
agen
Prote AG.
4.3 Removing and installing upper coolant
pipe
Special tools and workshop equipment required
♦ Hose clamp pliers - VAS 6340-
4. Coolant pipes 227
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Spring-type clip pliers - VAS 6362-
n AG. Volkswagen AG do
wage es n
Removing yV
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b
ed ran
– Remove air filter
thor housing ⇒ page 319 .
is tee
or
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– Drain coolant
ss ⇒ page 194 .
ce
e
nl
pt
– Unscrew bolt -2-.
du
an
itte
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erm
– Loosen hose clips -1- and -3- and pull off coolant pipe.
ab
ility
ot p
– Remove top coolant pipe at front.
wit
, is n
h re
Installing
hole
spec
es, in part or in w
Install in reverse order of removal, observing the following:
t to the co
– Add coolant ⇒ page 194 .
Specified torques
rrectness of i
♦ ⇒ “4.1 Assembly overview - coolant pipes”, page 222
l purpos
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
nform
ercia
4.4 Removing and installing left coolant pipe
m
at
om
ion
c
Special tools and workshop equipment required
in t
or
his
ate
♦ Release lever - 80 - 200-
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
228 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
n AG. Volkswagen AG do
♦ Hose clamps to 25 mm - 3094- lkswage es n
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ir se tee
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ss
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pt
an
d
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♦ Drip tray for workshop hoist - VAS 6208-
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♦ Spring-type clip pliers - VAS 6362-
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Prote AG.
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
– Remove air filter housing ⇒ page 319 .
– Lay wiring harnesses -arrows- and electrical connector -1- on
bracket to side.
Instructions for hose connections ⇒ page 246
4. Coolant pipes 229
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove air intake hose. To do this, loosen hose clips -1- and
-2-.
– Unscrew bolts -2-, -5- and -arrows-.
– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
– Loosen hose clip -3- and remove left air pipe.
– Place drip tray - VAS 6208- beneath engine.
– Clamp off coolant hoses with hose clamps to 25 mm - 3094-
and loosen hose clips -1- and -4-.
– Pull coolant hoses off left coolant pipe.
– Remove rear left coolant pipe.
Installing
Install in reverse order of removal. During this procedure, observe gen AG. Volkswagen AG d
the following: Vol
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♦ Hose unions and air intake pipes and hoses must be free of
du
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oil and grease before installation.
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ility
♦ Secure all hose connections with the hose clips corresponding
ot p
wit
to original equipment ⇒ Electronic parts catalogue (ETKA) .
, is n
h re
hole
spec
– Add coolant ⇒ page 194 .
es, in part or in w
t to the co
Specified torques
♦ ⇒ “4.1 Assembly overview - coolant pipes”, page 222
rrectness of i
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
l purpos
4.5 Removing and installing right coolant
nform
ercia
pipe
m
at
om
Special tools and workshop equipment required
on
c
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or
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
230 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Hose clamps to 25 mm - 3094-
♦ Drip tray for workshop hoist - VAS 6208-
♦ Spring-type clip pliers - VAS 6362-
AG. Volkswagen AG d
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Removing
spec
es, in part or in w
– Loosen bolt -1-. Unscrew bolt -2- and nut -3-.
t to the co
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
rrectness of i
– Remove noise insulation ⇒ General body repairs, exterior;
l purpos
Rep. gr. 66 ; Body front; Noise insulation .
– Remove front right wheel housing liner ⇒ General body re‐
nform
ercia
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Front wheel
housing liners .
m
a
com
tion in
– Place drip tray - VAS 6208- beneath engine.
r
te o
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t.
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.
4. Coolant pipes 231
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull connector -3- off radiator outlet coolant temperature send‐
er - G83- .
– Clamp off coolant hoses using hose clamps, up to 25 mm -
3094- .
– Loosen hose clips -arrows- and pull coolant hoses off right
coolant pipe.
– Unscrew nut -1- and bolt -2- and remove right coolant pipe.
Installing
Install in reverse order of removal, observing the following:
– Add coolant ⇒ page 194 .
Specified torques
♦ ⇒ “4.1 Assembly overview - coolant pipes”, page 222
AG. Volkswagen AG d
agen oes
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nl
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Prote AG.
232 Rep. gr.19 - Cooling
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
21 – Turbocharging/supercharging
1 Turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 233
⇒ “1.2 Removing and installing turbocharger ”, page 237
⇒ “1.3 Removing and installing charge pressure control solenoid
valve N75 ”, page 242
1.1 Assembly overview - turbocharger
Note
♦ Sealed bolts and nuts must not be loosened.
♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before installing the turbocharger, fill the oil
wage
n Asupply channel
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(smaller diameter) with a »splash« Voof
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♦ After installing turbocharger,
sa
u run engine for about 1 minute at ra
c
idling speed to ensure that
s oil is supplied to turbocharger.
ce
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nl
pt
du
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itte
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ab
ility
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es, in part or in w
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Prote AG.
1. Turbocharger 233
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Exhaust gas recirculation
pipe
❑ With flexible joint; do not
bend flexible joint - risk
of cracking
2 - Seal
❑ Renew after removal
3 - Bolts
❑ Specified torque
⇒ Item 1 (page 188)
4 - Union
❑ With oil supply line and
oil return line.
❑ Before installing, ensure
that oil supply line is not
blocked.
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 189 lkswage es n
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5 - Seal o
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❑ Renew after removal au ac
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6 - Nut
un
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❑ 24 Nm
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7 - Heat shield
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8 - Turbocharger
h re
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❑ Must only be renewed
spec
urposes, in part or in wh
together with exhaust
t to the co
manifold and position
sender for charge pres‐
sure positioner - G581- .
rrectne
❑ Installation position of
connecting hose at tur‐
s
bocharger ⇒ page 236
s o
cial p
f
❑ Note tightening sequence and installation procedure ⇒ page 236 .
inform
❑ Removing and installing ⇒ page 237
mer
atio
m
9 - Retaining ring
o
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❑ Installation possible in one position only.
thi
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❑ Installation position in pulsation damper ⇒ page 236 .
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10 - O-ring
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❑ Renew after removal C py
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11 - Pulsation damper cop Vo
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❑ Installation position of intake hose at pulsation damper ⇒ page 236 Prote AG.
12 - Bolt
❑ 9 Nm
13 - Intake connecting pipe
14 - Bolt
❑ Attached in inlet connection.
❑ 9 Nm
15 - O-ring
❑ Renew after removal
234 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
16 - Bracket
❑ For electrical cables
17 - Bolt
❑ 8 Nm
18 - Heat shield
19 - Seal
❑ Renew after removal
20 - Nut
❑ Renew after removal
❑ Note tightening sequence and installation procedure ⇒ page 236 .
❑ 25 Nm
21 - Exhaust gas temperature sender 1 - G235-
❑ Fitting position ⇒ page 236
❑ Removing and installing ⇒ page 351
22 - Bolt
❑ 20 Nm
23 - Support
❑ for turbocharger
❑ Before installing oil supply line, ensure that it is not blocked
❑ Before installing, fill turbocharger with engine oil through oil supply line connection
❑ Removing and installing ⇒ page 189
24 - Bolt
❑ Specified torque ⇒ Item 7 (page 188)
25 - O-ring
❑ Various diameters. AG. Volkswagen AG d
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❑ Renew after removal by Vo l not
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26 - Banjo bolt thor eo
au ra
❑ Specified torque
ss ⇒ Item 9 (page 188) c
ce
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nl
27 - Oil seals
pt
du
an
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❑ Renew after removal
erm
ab
ility
ot p
28 - Banjo bolt
wit
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❑ Specified torque ⇒ Item 10 (page 188)
h re
hole
spec
29 - O-ring
es, in part or in w
t to the co
❑ Renew after removal
30 - Nuts
rrectness of i
❑ Specified torque ⇒ Item 5 (page 188)
l purpos
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Prote AG.
1. Turbocharger 235
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Tightening sequence and procedure
♦ Position turbocharger on studs on cylinder head.
♦ Tighten nuts -1- to -8- in specified sequence. Then, tighten
nuts again in specified sequence.
Installation position of intake hose at turbocharger
– Fit connecting hose in such a way that the “extension” -2- of
the connecting hose is in contact with the corner of the name‐
plate -2-.
AG. Volkswagen AG d
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Installation position of connecting hose Volksw not
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– Install connecting hose in such a way that marking h-1-
oris on con‐ nte
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necting hose is opposite marking -2- on pulsation
s autdamper. ra
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urposes, in part or in wh
Installation position of exhaust gas temperature sender with an‐ t to the co
rrectne
gled cable guide
ss o
Note
cial p
f inform
mer
When installing the exhaust temperature sender with angled ca‐
atio
m
ble guide, adhere to dimension -a- of 3 … 5 mm from the turbo‐
o
n
c
charger support threaded connection.
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Installation position of O-ring and seals in pulsation damper pyri by
Vo
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Prote AG.
236 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Damper
❑ With grooves
2 - O-ring
3 - Seal
❑ With spring
AG. Volkswagen AG d
agen oes
olksw not
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tho eo
au ra
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nl
pt
du
1.2 Removing and installing turbocharger an
itte
y li
erm
ab
ility
ot p
Special tools and workshop equipment required wit
, is n
♦ Lambda probe open ring spanner set - 3337-
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
1. Turbocharger 237
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Ratchet ring spanner - T10385-
♦ Tool insert, AF 17 mm - T10395-
Caution
If a mechanical fault is discovered on the turbocharger (e.g. a
destroyed compressor impeller), it is not sufficient to just renew
the turbocharger. To avoid any subsequent damage, the fol‐
lowing work must be carried out:
. Volkswagen AG
gen AG d
♦ Check air filter housing, air filter
Vol element and air inlet ho‐ ot gu
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ses for contamination. sed b y ara
n i tee
or
♦ Check the whole charge
au
th air path and charge air cooler for or
ac
foreign objects. ss
ce
e
nl
pt
♦ If foreign objects are discovered in the charge air system,
du
an
itte
clean the charge air path and, if necessary, renew the
y li
erm
ab
charge air cooler.
ility
ot p
wit
, is n
h re
hole
Removing
spec
es, in part or in w
Note safety precautions ⇒ page 1 .
t to the co
Observe rules for cleanliness ⇒ page 9 .
Instructions for hose connections ⇒ page 246
rrectness of i
– Remove particulate filter ⇒ page 345 .
l purpos
– Remove oil supply line and turbocharger support
⇒ page 189 .
nf
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orm
m
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t.
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Cop py
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by
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Prote
238
AG.
Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove air filter housing with air mass meter and connecting
pipe ⇒ page 319 .
AG. Volkswagen AG d
agen oes
olksw not
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rise nte
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au ra
ss c
– Press release buttons and remove hose -1- for venting crank‐
ce
le
un
case.
pt
an
d
itte
y li
– Unclip vacuum lines -arrows- and place to one side.
rm
ab
pe
ility
– Unscrew bolt -2- (captive bolt). Twist intake hose -3- clockwise
ot
wit
, is n
out of its holder and remove it.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Open heat shield gaiter -1- from charge pressure servo posi‐ nform
tion sender - G581- -3-.
mercia
– Disconnect and pull off electrical connector -2- on charge
a
com
tio
pressure servo position sender - G581- -3-.
n in
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co lksw
by
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Prote AG.
– Open bracket -2- and unhook vacuum hose -1-.
– Pull off vacuum hose -1- from vacuum unit on turbocharger.
1. Turbocharger 239
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Separate electrical connector -2- for exhaust temperature
sender 1 - G235- and move electrical wire aside.
– Carefully take the line out of the brackets on plenum chamber
bulkhead and on turbocharger.
– Unscrew bolt -1- from charge air pipe and undo the two clips
of the connecting hose.
– Remove pulsation damper.
– Unscrew bolts -arrows-. AG. Volkswagen AG d
agen oes
– Take off pulsation damper -2-. olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
lation.
rrectness of i
l purpos
nf
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orm
m
atio
om
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or c
thi
te
sd
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
240 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line.
– Unscrew bolts -arrows- and remove heat shield.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
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aut ra
ss c
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un
pt
an
d
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wit
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spec
urposes, in part or in wh
t to the co
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cial p
f inform
mer
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om
n
c
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sd
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
1. Turbocharger 241
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew nuts -arrows-.
– Remove turbocharger together with exhaust manifold from
cylinder head and turn so that the intake side is facing down‐
wards. Remove turbocharger together with exhaust manifold n AG. Volkswagen AG do
downwards. lkswage es n
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byV ua
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Installing o
ir se
ran
tee
th or
u
Install in reverse order of removal, observing the following:
ss
a ac
ce
e
nl
pt
du
an
itte
Note
y li
erm
ab
ility
ot p
♦ Renew seals, gaskets, O-rings and self-locking nuts.
wit
, is n
h re
♦ Fill turbocharger with engine oil at connection for oil supply hole
spec
line.
es, in part or in w
t to the co
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
rrectness of i
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic parts catalogue (ETKA) .
l purpos
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger. Do
nform
ercia
not rev engine immediately.
m
at
♦ Fit heat shield sleeves in the same place when installing.
om
ion
c
in t
or
his
ate
do
riv
Caution
p
cum
for
en
ng
t.
Before installing, check whether flexible joint of oil return line op
yi Co
is bent and thus stretched. If this is the case, micro-fractures
C py
t. rig
gh
may have been caused and this will cause leaks. If necessary,
ht
pyri by
Vo
renew oil return line before installing turbocharger.
co lksw
by
cted agen
Prote AG.
– Installing intake hoses with screw-type clips ⇒ page 246 .
– When fitting intake connecting pipe to turbocharger, ensure
that intake connecting pipe is correctly seated on stud of tur‐
bocharger. -arrow-.
– Install exhaust gas recirculation pipes ⇒ page 357 .
– Installing exhaust temperature sender 1 - G235-
⇒ page 351 .
– Connect vacuum hoses ⇒ page 270 .
– Install air filter housing ⇒ page 319 .
– Install particulate filter ⇒ page 345 .
Specified torques
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 233
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
♦ ⇒ “2.2 Assembly overview - particulate filter”, page 344
1.3 Removing and installing charge pres‐
sure control solenoid valve - N75-
Special tools and workshop equipment required
242 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engineAG(1.6
. Volkl sengine,
wagen A common rail) - Edition 07.2019
n G do
wage es n
Volks ot g
♦ Torque wrench - V.A.G 1410- ed
by ua
ran
oris tee
th or
au ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
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h re
ole,
spec
urposes, in part or in wh
t to the co
rrectne
♦ Hose clamp pliers - VAS 6340-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Removing Prote AG.
– Press release buttons and remove hose -1- for venting crank‐
case.
– Unclip vacuum hoses -arrows- and place to one side.
– Remove intake hose -3- on air filter.
– Unscrew bolt -2- (captive bolt). Twist intake hose -3- clockwise
out of its holder and remove it.
1. Turbocharger 243
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull off vacuum hoses -4-, -5- and -6- from charge pressure
control solenoid valve - N75- -2-.
– Release connectors -7- and pull off.
– Unscrew nuts -3- and remove charge pressure control sole‐
noid valve - N75- -2-.
Installing
Install in reverse order of removal, observing the following:
Caution
Do not kink, twist or crush the vacuum lines when routing vac‐
uum lines. This may cause breakdowns.
Push all hoses onto stop or at least 10 mm onto the respective
connection.
AG. Volkswagen AG d
– Install suction hose on turbocharger ⇒ page 233 . agen oes
olksw not
y V gu
d b ara
ise nte
– Tighten nuts -3-. thor eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– When fitting intake connecting pipe to turbocharger, ensure
l purpos
that intake connecting pipe is correctly seated on stud of tur‐
bocharger. -arrow-.
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orm
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Prote AG.
244 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Charge air system
⇒ “2.1 Assembly overview - charge air system”, page 245
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 246
⇒ “2.3 Removing and installing charge air cooler”, page 247
⇒ “2.4 Removing and installing charge air pipe”, page 249
⇒ “2.5 Removing and installing charge air pressure sender G31 /
intake air temperature sender G42 ”, page 250
⇒ “2.6 Checking charge air system for leaks”, page 250
2.1 Assembly overview - charge air system
1 - Charge air cooler
❑ Removing and installing
⇒ page 247
2 - Seal
3 - Bolt
❑ 5 Nm
4 - Mountings
5 - Mountings
6 - Screw-type clamp
❑ Instructions for hose
connections
⇒ page 246 wagen AG. Volkswagen AG does
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⇒ page 250
hole
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10 - O-ring
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❑ Renew after removal
11 - Air intake pipe
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12 - Screw-type clamp
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❑ Instructions for hose
connections
⇒ page 246
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13 - Air intake hose
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14 - Bolt
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❑ 9 Nm
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15 - Grommet
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2. Charge air system 245
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
16 - Air intake hose
17 - Air intake pipe
18 - Sleeve
19 - Bolt
❑ 9 Nm
20 - Grommet
❑ Renew if damaged
21 - Air intake hose
22 - Seal
Installing air hoses with screw-type clips
Note
In order to be able to securely attach the air hoses on their con‐
nections, the worm screws of the used hose clips have to be
sprayed with penetrating spray before installing.
Specified torques for
1- Hose clip -a- = 13 mm wide: 5.5 Nm
Volkswagen AG
2- Hose clip -b- = 9 mmsw
wide:
agen 3 Nm
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2.2 Assembly overview - charge-air hose
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It is essential for the screw-type clamps on the charge air lines
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to be tightened to 5.5 Nm. If the tightening torque is too low or
h re
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too high, the charge air hose may slip off the charge air pipe
spec
urposes, in part or in wh
when the vehicle is being driven.
t to the co
Conventional screw-type clips are used on the hose connections
rrectne
on the “intake side”.
Screw-type clips with “barbs” -arrows- are used on the hose con‐
ss
nections on the “discharge side”.
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Caution
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• Do not loosen these hose clips and pull them back over
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or
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the hose. Risk of damage to hose!
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• If a clamp has been removed, it must be renewed together
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246 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Screw-type clips with locking hooks -arrows- may only be re‐
leased.
– Loosen bolt of screw-type clips -1- sufficiently to allow for re‐
moving hoses.
Screw-type clamps that have only been loosened can be re-used.
Hose and clamp are supplied together as one spare part.
– When installing, does not use any fluid containing oil, silicone
or grease. Only use clean water.
Note
♦ Check all air hoses and pipes for firm seating and leaks before
carrying out tests or repairs.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the same type of hose clips
as original equipment ⇒ Electronic parts catalogue .
♦ In order to be able to securely attach the air hoses on their
connections, the worm screws of the used hose clips have to
be sprayed with penetrating spray before installing.
AG. Volkswagen AG d
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The screw-type clips -A- on the charge air lines must always
a ra
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be tightened as specified ⇒ page 246 . If the torque is too low
ce
le
un
pt
or too high, the charge air hose may slip off the corrugated pipe
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connection or the charge air pipe when the vehicle is used.
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2.3 Removing and installing charge air cool‐
rrectne
er
Removing
ss o
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– Open air intake cover. To do this, carefully release the catches
inform
-arrows-.
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2. Charge air system 247
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -arrows- for air intake -1- and take connecting
hose -2- out of guide.
– Press in locking lugs -1- and -3- and pull connecting hose
age-4-
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– Set lock carrier to service position ⇒ General risbody repairs, tee
tho
exterior; Rep. gr. 50 ; Body - front; Lockscarrier
au . or
ac
s
– Remove air filter ⇒ page 319 .
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– Remove radiator together with connected coolant lines
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⇒ page 219 . Then, secure radiator with wire.
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– Unscrew bolts -arrows- from charge air cooler.
– Swing charge air cooler backwards slightly.
rrectness of i
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– Unscrew bolt from lower right refrigerant line bracket on
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– Remove charge air cooler upwards.
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Installing
Install in reverse order of removal, observing the following:
Instructions for hose connections ⇒ page 246
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front; Lock carrier .
– Installing radiator ⇒ page 219 .
Specified torques
♦ ⇒ “2.1 Assembly overview - charge air system”, page 245
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 217
248 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.4 Removing and installing charge air pipe
Sequence of operations
– Disconnect earth strap at battery with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery.
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery .
– Remove air filter housing with air mass meter and connecting
pipe ⇒ page 233 .
Instructions for hose connections ⇒ page 246
– Loosen clips -1- and -2- on connecting hose to pulsation
damper. Unscrew securing bolt -3- from charge air pipe.
– Unscrew charge air pipe bolt -arrow-. Pull connecting hose off
pulsation damper as far as possible.
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– Unclip top coolant hose on charge air pipe -arrow-. t to the co
rrectness of i
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– Unclip wiring harnesses from charge air pipe -arrows-. C py
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2. Charge air system 249
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove connecting hose -arrow-.
– Remove bolts -arrows- of charge air pipe.
– Take out charge air pipe.
Installing
Install in reverse order of removal, observing the following:
– Renew any damaged cable ties and clips.
Specified torques
♦ ⇒ “2.1 Assembly overview - charge air system”, page 245
2.5 Removing and installing charge. Vair pres‐
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sure sender - G31- / intake
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– Remove noise insulation ⇒ General body repairs, exterior;
nl
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Rep. gr. 66 ; Body front; Noise insulation .
itte
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– Pull connector -2- off charge air pressure sender - G31- / in‐
ility
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take air temperature sender - G42- .
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– Unscrew bolts -1- and pull charge pressure sender - G31- /
hole
spec
intake air temperature sender - G42- out of air pipe.
es, in part or in w
t to the co
Installing
Install in reverse order of removal, observing the following:
rrectness of i
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 66 ; Body - front; Noise insulation .
l purpos
Specified torques
nform
ercia
♦ ⇒ “2.1 Assembly overview - charge air system”, page 245
m
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2.6 Checking charge air system for leaks
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Special tools and workshop equipment required
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250 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder dieselgeengine
n AG. Vo(1.6
lkswalgengine,
en AG
d
common rail) - Edition 07.2019
wa oes
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♦ Charge air system tester - V.A.G is1687-
ed
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♦ Adapter - V.A.G 1687/10-
s
♦ Engine bung set - VAS 6122-
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Removing
– Remove crankcase breather hose -arrow- from air pipe. To do
this, press release buttons.
– Seal union with a bung -2- (diameter 28 mm) from engine bung
set - VAS 6122- and secure with a clip -1-.
2. Charge air system 251
Caddy 2011 ➤ AG. Volkswagen AG d
agen
4-cylinder diesel engine (1.6 l engine, common rail)V-oEdition
lksw 07.2019 oes
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– Remove intake hose -1- from air filter. tho
r eo
s au ra
c
– Insert adapter - V.A.G 1687/10- into intake hose
s -1- and se‐
ce
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cure with a clip.
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Prepare charge air system tester - V.A.G 1687- as follows:
erm
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– Unscrew pressure control valve -2- completely and close
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valves -3- and -4-.
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To turn the pressure regulating valve -2- the knob must be pulled Prote
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upwards.
– Connect charge air system tester - V.A.G 1687- to adapter -
V.A.G 1687/10- as shown.
252 Rep. gr.21 - Turbocharging/supercharging
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Connect compressed air hose -1- (compressed air supply) to
charge air system tester - V.A.G 1687- , using a standard con‐
necting piece.
Note
Drain water in sight glass by removing drain plug -6-.
– Open valve -3-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is too
high, this can cause damage to the charge air system.
– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
– Open valve -4- and wait until test circuit is full. If necessary,
re-adjust pressure to 0.5 bar.
– Check charge air system for leaks as follows:
♦ by listening
♦ by feeling
♦ with leak detector spray
♦ or with the ultrasonic tester - V.A.G 1842- .
Note
n AG. Volkswagen AG do
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♦ Slight leaks on the intake side of turbocharger are permissible,
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as the intake hoses are not designed for high-pressure.ised b ua
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♦ A small amount of air escapes through the valvessand
au enters
t or
ac
the engine. Therefore a holding pressure test is not
s possible.
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♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
an
itte
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♦ Depressurise test circuit by detaching coupling from adapter -
ility
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V.A.G 1687/10- before removing adapter.
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ate
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Prote AG.
2. Charge air system 253
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
23 – Mixture preparation - injection
1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 254
n AG. Volkswagen A
⇒ “1.2 Overview of fitting
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⇒ “1.3 Assembly
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⇒ “1.4 Checking fuel system for leaks”, page 268
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⇒ “1.5 Filling/bleeding fuel system”, page 268
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1.1 Schematic overview - fuel system
ility
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The diesel direct injection system control unit is equipped with an
h re
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event memory. Read event memory before and after making re‐
spec
pairs or adjustments.
es, in part or in w
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WARNING
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♦ Read through the rules for cleanliness and the instructions
l purpos
for working on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
nform
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before starting work and while working on the fuel system.
m
♦ If components of the fuel system between the tank and the
at
om
io
high-pressure fuel pump are removed or renewed, the fuel
n
c
in t
r
system must be filled to be bled ⇒ page 268 . (It is im‐
o
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te
portant not to allow the high-pressure pump to run while
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still empty.)
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– Connect ⇒ Vehicle diagnostic tester.
– Carry out function “Fill/bleed high-pressure pump/fuel system”
⇒ page 268 .
The diesel direct injection system control unit is equipped with an
event memory. Read event memory before and after making re‐
pairs or adjustments.
254 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Fuel
❑ With fuel pump - G6-
2 - Fuel filter
❑ Assembly overview -
fuel filter
❑ Removing and installing
fuel filter
3 - High-pressure pump
❑ After renewing, a first
fuel filling “must” be per‐
formed (never allow
pump to run while dry) agen
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⇒ page 268 . Volksw not
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❑ Removing and installing rise
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⇒ page 302 autho eo
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4 - Fuel metering valve - N290-
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❑ Do not open.
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5 - Fuel pressure sender - G
ility
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247-
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❑ Installing and removing
h re
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⇒ page 329
spec
urposes, in part or in wh
6 - High-pressure accumulator
t to the co
7 - Fuel pressure regulating
valve - N 276-
rrectne
❑ Removing and installing
⇒ page 324
ss
❑ 80 Nm
o
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8 - Pressure retention valve
mer
with fuel return lines
atio
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❑ The fuel return lines
o
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must not be dismantled.
thi
te
They can only be re‐
sd
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newed together with the pressure retention valve as one unit.
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❑ The non-return valve has the task of maintaining a residual pressure (control volume) of approx. 1 bar yi
t.
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in the fuel return lines. t. Cop py
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❑ This residual pressure is required for the control function of the piezo injectors.
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❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
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❑ The pressure retention valve is installed in the fuel return lines just before the metal return line.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
❑ Check pressure retention valve ⇒ page 296 .
9 - Injectors (piezo injectors)
❑ Injector, cylinder 1 - N30-
❑ Injector, cylinder 2 - N31-
❑ Injector, cylinder 3 - N32-
❑ Injector, cylinder 4 - N33-
❑ Installing and removing ⇒ page 290
1. Injection system 255
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.2 Overview of fitting locations - injection n AG. Volkswagen AG
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The diesel direct injection system control unit is equippedswith
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event memory. Read event memory before and after making re‐
s
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pairs or adjustments.
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Components A to I are not shown in the illustration.
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1 - Pressure differential sender
h re
- G505-
hole
spec
❑ Fitting location
es, in part or in w
t to the co
⇒ page 262
❑ Adaptation is necessary
after this component
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has been renewed
⇒ Vehicle diagnostic
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tester
❑ Removing and installing
nform
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⇒ page 324
m
at
2 - Hall sender - G40- (cam‐
om
ion
shaft position sensor)
c
in t
or
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❑ Fitting location
at
do
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⇒ page 262
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for
❑ Electrical connection for
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Hall sender - G40-
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⇒ page 262
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❑ 10 Nm cop Vo
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❑ Removing and installing
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⇒ page 372
3 - Exhaust gas temperature
sender 3 - G495-
❑ Fitting location
⇒ page 263
❑ Electrical connector for
exhaust temperature
sender 3 - G495-
⇒ page 264
4 - Lambda probe - G39- with
Lambda probe heater - Z19-
❑ Fitting location
256 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
⇒ page 263
❑ 50 Nm
❑ Removing and installing ⇒ page 321
5 - Engine control unit - J623-
❑ Fitting location ⇒ page 259
❑ Removing and installing ⇒ page 334
6 - Injectors (piezo injectors)
❑ Fitting location ⇒ page 263
❑ Removing and installing ⇒ page 290
7 - Position sender for charge pressure positioner - G581-
❑ Fitting location ⇒ page 263
8 - Fuel pressure regulating valve - N276-
❑ Fitting location ⇒ page 261
❑ 80 Nm
❑ Removing and installing ⇒ page 324
9 - Charge pressure control solenoid valve - N75-
❑ Fitting location of connector ⇒ page 264
10 - Electrical connector AG. Volkswagen AG d
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❑ for exhaust gas temperature sender 3 - G495- . by
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❑ for exhaust gas temperature sender 1 - G235- . horis nte
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❑ For Lambda probe - G39- . ss a ra
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❑ Fitting location ⇒ page 263
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11 - Air mass meter - G70-
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❑ Removing and installing ⇒ page 323
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12 - Radiator outlet coolant - G62-
h re
hole
❑ Fitting location ⇒ page 264
spec
es, in part or in w
❑ Removing and installing ⇒ page 214
t to the co
13 - Engine speed sender - G28-
❑ Fitting location ⇒ page 263
rrectness of i
❑ 4.5 Nm
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14 - Intake manifold flap potentiometer - G336-
❑ If present
nf
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orm
15 - Exhaust gas recirculation cooler changeover valve - N345-
m
atio
m
❑ Fitting location ⇒ page 263
o
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16 - Pump for exhaust gas recirculation cooler - V400-
t
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❑ Fitting location ⇒ page 261
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17 - Throttle valve module - GX3-
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❑ Fitting location ⇒ page 261
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❑ Assembly overview - intake manifold ⇒ page 311 .
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❑ Removing and installing ⇒ page 316 Prote AG.
18 - Charge air pressure sender - G31- with intake air temperature sender - G42-
❑ Fitting location ⇒ page 261
❑ Removing and installing ⇒ page 250
1. Injection system 257
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
19 - Glow plugs
❑ Fitting location ⇒ page 261
❑ Glow plug 1 - Q10-
❑ Glow plug 2 - Q11-
❑ Glow plug 3 - Q12-
❑ Glow plug 4 - Q13-
❑ Removing and installing ⇒ page 369
20 - Connection of fuel supply line from fuel filter
❑ Fitting location ⇒ page 261
21 - Connection of fuel return line to fuel filter
❑ Fitting location ⇒ page 261
22 - Fuel high-pressure pump with fuel metering valve - N290-
❑ Fitting location ⇒ page 261
❑ Do not open fuel metering valve - N290-
❑ After renewing, a first fuel filling “must” be performed (never allow the pump to run while it is still empty)
⇒ page 268 .
❑ Removing and installing ⇒sw page AG. Volkswagen AG d
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23 - Connection of fuel supply by line (high pressure line) to high upressure
ara accumulator
ed nte
ris
❑ Fitting locationau⇒
th page 261
o eo
ra
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24 - Fuel temperature sender - G81-
ce
le
un
pt
❑ In fuel supply line
an
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itte
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❑ Fitting location ⇒ page 261
erm
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ility
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25 - Radiator outlet coolant temperature sender - G83-
wit
is n
h re
❑ Fitting location ⇒ page 262
ole,
spec
❑ Removing and installing ⇒ page 215
urposes, in part or in wh
t to the co
26 - Fuel pressure sender - G247-
❑ Fitting location ⇒ page 261
rrectne
❑ Removing and installing ⇒ page 329
27 - Fuel filter
ss o
❑ Assembly overview - fuel filter
cial p
f in
❑ Fuel filter: Renew
form
mer
atio
A - Fuel system pressurisation pump - G6-
om
n
c
❑ Fitting location ⇒ page 260
i
or
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sd
a
B - Low heat output relay - J359- and high heat output relay - J360-
iv
o
pr
cum
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❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
fo
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C - Brake light switch - F- and brake pedal switch - F47- ht. Cop py
rig
❑ Fitting location ⇒ page 260 rig ht
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❑ In footwell on brake pedal
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D - Clutch position sender - G476-
❑ Fitting location ⇒ page 260
❑ Only fitted to vehicles with a manual gearbox
E - Accelerator position sender - G79- and accelerator position sender 2 - G185-
❑ Fitting location ⇒ page 259
❑ Removing and installing
F - Exhaust gas recirculation valve 1 - GX5-
❑ Fitting location ⇒ page 264
258 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
G - Exhaust gas temperature sender 1 - G235-
❑ Fitting location ⇒ page 264
❑ Assembly overview - lambda probes and exhaust gas temperature senders ⇒ page 350 .
❑ Removing and installing ⇒ page 351
H - Exhaust gas temperature sender 4 - G648-
❑ Fitting location ⇒ page 264
❑ Assembly overview - lambda probes and exhaust gas temperature senders ⇒ page 350 .
❑ Removing and installing ⇒ page 354
I - Particulate filter
❑ Secured to underbody
❑ Shared component with a catalytic converter
❑ Adaptation is necessary after this component has been renewed
❑ Removing and installing ⇒ page 345
An adaptation must be performed after renewing pressure differ‐
ential sender - G505- and/or particulate filter ⇒ Vehicle diagnostic
tester.
Fitting location of engine control unit - J623-
Engine control unit can be found in plenum chamber.
Removing and installing ⇒ page 334
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Accelerator position sender - G79- and accelerator position send‐ ss
ce
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er 2 - G185-
un
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Removing and installing
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Note
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spec
The accelerator pedal position sender - G79- and accelerator
es, in part or in w
t to the co
pedal position sender 2 - G185- are integrated in the accelerator
pedal module and cannot be replaced singly.
rrectness of i
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Prote AG.
1. Injection system 259
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Brake light switch - F- and brake pedal switch - F47- -1-
Integrated functions: Clutch pedal switch for engine starting -
F194- and clutch pedal switch - F36- (only in the case of manual
gearboxes)
Clutch position sender - G476-
Fuel system pressurisation pump - G6-
Removing and installing AG. Volkswagen AG d
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spec
urposes, in part or in wh
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Cop py
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260
cted agen
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Rep. gr.23 - Mixture preparation - injection
AG.
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
n AG. Volkswagen AG do
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Locations byV
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1 - Fuel pressure
tho sender - G247- tee
or
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2 - Glow plug 1 - Q10-
ss
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3 - Glow plug 2 - Q11-
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4 - Glow plug 3 - Q12-
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5 - Glow plug 4 - Q13-
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6 - Fuel pressure regulating valve - N276-
spec
es, in part or in w
7 - Exhaust gas recirculation cooler changeover valve - N345-
t to the co
8 - Throttle valve module - GX3-
9 - Connection of fuel supply line from fuel filter
rrectness of i
10 - Connection of fuel return line to fuel filter
l purpos
11 - Fuel metering valve - N290-
nform
ercia
12 - Connection of fuel supply line (high pressure line) to high
m
pressure accumulator
a
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tion in
13 - Fuel temperature sender - G81-
r
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Pump for exhaust gas recirculation cooler - V400-
r
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2 - Pump for exhaust gas recirculation cooler - V400-
n
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Cop py
♦ On front of engine
t. rig
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Assembly overview ⇒ page 222
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Charge air pressure sender - G31- with intake air temperature
sender - G42- -1-
1- Charge air pressure sender - G31- with intake air tempera‐
ture sender - G42-
♦ On air pipe on right
Removing and installing ⇒ page 250
1. Injection system 261
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Hall sender - G40-
♦ Next to toothed pulley of camshaft -arrow-.
Removing and installing ⇒ page 372
AG. Volkswagen n AG do
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Connector -1- for Hall sender - G40-
ole,
spec
urposes, in part or in wh
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Locations
iva
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1- Pressure differential sender - G505-
en
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2- Fuel pressure sender - G247-Cop py
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Radiator outlet coolant temperature sender - G83-
2 - Radiator outlet coolant temperature sender - G83-
♦ In coolant pipe on right above the alternator.
Removing and installing ⇒ page 215
262 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Engine speed sender - G28-
1- Engine speed sender - G28-
2- Sender wheel
Removing and installing ⇒ page 371
Exhaust gas recirculation cooler changeover valve - N345-
3 - Exhaust gas recirculation cooler changeover valve - N345-
♦ On front left of intake manifold
Components on engine
1- Pressure differential sender - G505- AG. Volkswagen AG d
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2- Exhaust gas temperature sender 3 - G495- d by
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3- Lambda probe - G39- ut
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4- Position sender for charge pressure positioner - G581- s
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5- Injectors (N30 to N33)
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6- Glow plugs (Q10 to Q13)
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7- Fuel pressure sender - G247-
, is n
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spec
es, in part or in w
Installation locations and plug-in connections
t to the co
1- Electrical connector for exhaust temperature sender 3 -
G495-
rrectness of i
2- Electrical connector for exhaust temperature sender 1 -
l purpos
G235-
3- Electrical connector for Lambda probe - G39-
nform
ercia
1 - Electrical connector for charge pressure control solenoid valve
m
at
- N75-
om
ion
c
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or
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ate
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Cop py
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Prote AG.
1. Injection system 263
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Location and connector
1- Electrical connector for exhaust temperature sender 4 -
G648-
Charge pressure control solenoid valve - N75-
Removing and installing ⇒ page 242
Coolant temperature sender - G62- -1-
Removing and installing ⇒ page 214
AG. Volkswagen AG d
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Components on rear of engine
rm
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1- Lambda probe - G39-
ot
wit
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2- Exhaust temperature sender 1 - G235- in the turbocharger
hole
spec
3- Exhaust gas temperature sender 4 - G648-
es, in part or in w
t to the co
4- Vacuum unit for exhaust gas recirculation cooling system
5- Exhaust gas recirculation valve 1 - GX5-
rrectness of i
6- Electrical connector on exhaust gas recirculation valve 1 -
l purpos
GX5-
nform
mercia
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Cop py
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Prote AG.
264 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.3 Assembly overview - fuel system
WARNING n AG. Volkswagen AG do
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♦ Read through the rules forsecleanliness
d b and the instructions ua
ran
for working on the fuel thsystem.
o
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♦ Always follow these rules for cleanliness and instructions
ss
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before starting work and while working on the fuel system.
un
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Caution
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hole
spec
To prevent the high-pressure fuel pump from running while it
es, in part or in w
is empty and to ensure that the engine starts quickly after parts
t to the co
have been renewed, it is important to observe the following:
♦ If components of the fuel system between the tank and the
rrectness of i
high-pressure fuel pump are removed or renewed, the ba‐
sic setting “Checking fuel supply pump” must be per‐
l purpos
formed to bleed the fuel system.
♦ If a fuel pump, fuel line (between fuel tank and high-pres‐
nform
ercia
sure fuel pump) or fuel filter are removed or renewed, the
basic setting “Checking fuel system pressurisation pump”
m
a
com
t
must be performed »once« before the engine is started for
ion in
the first time.
r
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♦ If the high-pressure fuel pump is removed or renewed, the
do
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c
basic setting “Checking fuel system pressurisation pump”
um
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must be performed »three times« before the engine is
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started for the first time. t. Cop py
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♦ Performing first fuel filling after installing high-pressure yri
p by
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pump ⇒ page 268 .
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Prote AG.
1. Injection system 265
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Fuel return line
❑ Flexible
❑ To fuel tank
❑ The fuel return line must
not be kinked, damaged
or blocked.
❑ The fuel return lines
must not be dismantled.
❑ Renew O-ring only if
necessary.
❑ The pressure retention
valve maintains a resid‐
ual pressure in the fuel
return lines.
❑ This residual pressure is
required for the control
function of the piezo in‐
jectors.
❑ Check pressure reten‐ n AG. Volkswagen AG do
tion valve ⇒ page 296 . lkswage es n
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2 - Fuel pressure regulating ir se
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valve - N276- autho
or
ac
❑ Renew after removal ss
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un
pt
❑ Removing and installing
an
d
itte
⇒ page 324
y li
erm
ab
❑ 80 Nm
ility
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❑ After renewing, re-adapt
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learnt values ⇒ Vehicle
ole,
spec
diagnostic tester
urposes, in part or in wh
t to the co
3 - Fuel return line
❑ Rigid.
rrectne
4 - Bolt
❑ 10 Nm
ss
5 - High-pressure pump
o
cial p
f in
❑ With fuel metering valve - N290- (do not open)
form
mer
❑ After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty)
atio
m
⇒ page 268 .
o
n
c
i
or
❑ Removing and installing ⇒ page 302
thi
te
sd
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6 - Bolt
pr
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❑ Specified torque ⇒ page 301
en
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7 - Hub t. C rig
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❑ With sender ring cop Vo
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❑ Use counterhold - T10051- to loosen and tighten. Prote AG.
❑ To remove, use puller - T40064- .
8 - Nut
❑ Specified torque ⇒ page 301
9 - Crankshaft
10 - Bolt
❑ Specified torque ⇒ page 301
11 - Bolt
❑ 10 Nm
266 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
12 - High-pressure line
❑ Between high-pressure pump and fuel rail
❑ Install so that component is not under tension
❑ For installation, the 17 mm tool insert - V.A.G 1331/6- and the support sleeve - T10411- are needed.
Note
♦ The high-pressure line may be
re-used after the following
checks:
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
♦ The inside of the line must be
free of deformations, constric‐
tions and damage.
♦ Corroded lines should no longer
be used.
❑ 28 Nm
13 - Fuel pressure sender - G247-
❑ 100 Nm
❑ Removing and installing ⇒ page 329
14 - High-pressure accumulator
❑ Removing and installing ⇒ page 286
15 - Bolt
❑ 22 Nm
16 - High-pressure lines
❑ When loosening and tightening, counterhold on the injector connection
❑ Between high pressure accumulator agenand injectors (piezo
AG. Volkswagen AG d injectors)
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❑ Install so that component
thoris
is not under tension eo
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Note
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an
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♦ Observe cylinder-specific mark‐
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ab
ings if reusing high-pressure
ility
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lines.
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♦ The high-pressure lines may be
hole
spec
re-used after the following
es, in part or in w
checks:
t to the co
♦ Check taper seat of respective
high-pressure line for deforma‐
rrectness of i
tion and cracks.
♦ The inside of the line must be
l purpos
free of deformations, constric‐
tions and damage.
nf
ercia
♦ Corroded lines should no longer
rm
m
atio
be used.
om
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or c
❑ 28 Nm
thi
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sd
iva
17 - Seal
r
rp
cu
o
m
f
❑ Renew if damaged ⇒ page 111 .
en
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t.
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Cop py
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rig ht
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Prote AG.
1. Injection system 267
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
18 - Seal
❑ Renew after removal
19 - Injectors (piezo injectors)
❑ The following components and seals/O-rings must be renewed each time on removal/installation: “bolt
for clamping piece”, “copper seal”, “O-ring of injector bore” and “retaining clip for return connection”.
❑ The following components must also be renewed when an injector is replaced: “bolt for clamping piece”
❑ Before re-using “high-pressure line”, perform visual check of taper seats for damage such as transverse
scores or corrosion. Always replace them if damaged.
❑ If removed piezo injectors, high-pressure lines and clamping pieces are to be reinstalled, they must
always be re-fitted in their original positions (i.e. on the same cylinder).
❑ Removing and installing ⇒ page 290
20 - Bolt
❑ Renew after removal
❑ Specified torque ⇒ page 280
21 - O-ring for fuel return lines
❑ Renew O-ring only if necessary.
❑ The following component must be renewed any time the fuel return line is removed and installed: “return
line retaining clip”.
❑ Removing and installing ⇒ page 296
1.4 Checking fuel system for leaks
– Clean all removed and re-installed fuel connections with brake
cleaner and then dry them.
– Allow engine to idle for 5 minutes without depressing acceler‐
ator pedal. Then, switch engine off. Fuel system will be bled n AG. Volkswagen AG do
automatically. lkswage es n
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– Check entire fuel system for leaks . ir se
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Renew the affected component if leakage still occurs after stight‐
s a ac
ening to the correct torque.
ce
le
un
pt
an
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– Then road test the vehicle, accelerating to full throttle at least
itte
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once. Then check high-pressure section of fuel system again
rm
ab
pe
for leakage.
ility
ot
wit
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hole
Note
spec
es, in part or in w
If there is still air in the fuel system, the engine can change to t to the co
emergency running mode during road test. Then, switch off en‐
gine and clear event memory. Then continue with a road test.
rrectness of i
l purpos
1.5 Filling/bleeding fuel system
Special tools and workshop equipment required
nform
ercia
♦ Vehicle diagnostic tester
m
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tion in
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Caution
thi
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iva
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After new or removed parts such as the fuel filter or fuel lines
fo
en
g
have been fitted, the high-pressure pump must be filled with
n
t.
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fuel before the engine is started for the first time. It is essential Cop py
t. rig
not to allow the high-pressure pump to run while still empty. gh ht
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Prote AG.
268 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
♦ When installing the high-pressure pump, it is essential to en‐
sure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.
♦ Vehicle must have fuel.
AG. Volkswagen AG d
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To bleed/fill theefuel
d by Vsystem, it is necessary to meet gthese
ua
ran condi‐
tions. horis tee
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ac
• Vehicle
ss must have fuel.
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• Fuel system temperature ≥ 15 °C
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• Temperature of fuel ≥ 15 °C
erm
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Proceed as follows to fill high-pressure pump and fuel system with
wit
is n
fuel:
h re
ole,
spec
– Connect ⇒ Vehicle diagnostic tester.
urposes, in part or in wh
t to the co
– Connect ⇒ Vehicle diagnostic tester and, depending on soft‐
ware version, perform function “Bleed fuel system” or “Fill/
bleed fuel system”.
rrectne
Note
ss o
cial p
f in
♦ The fuel pumps will now be actuated for a total of three mi‐
form
mer
nutes. The process must not be terminated prematurely.
atio
om
♦ There could still be air bubbles in the fuel system after the
n
c
i
or
bleeding procedure.
thi
te
sd
iva
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pr
cum
– Start engine and visually inspect fuel system for leaks.
r
fo
en
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Cop py
Caution ht. rig
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Do not carry out starting attempts for longer than 15 seconds.
cted agen
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If engine does not start, repeat bleeding process twice.
– After filling fuel system and successfully starting engine, allow
it to run for a few minutes at a moderate speed. Switch off
engine.
– Check fuel system for leaks.
– Read out event memory and, if necessary, clear event mem‐
ory entry.
– Then, road-test the vehicle for more than 20 km with full throttle
acceleration at least once. Then check high-pressure section
of fuel system again for leakage.
Note
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Then, switch off en‐
gine and clear event memory. Then continue with a road test.
– Read event memory.
1. Injection system 269
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 270
⇒ “2.2 Checking vacuum system”, page 271
⇒ “2.2.1 Checking non-return valve and vacuumAG. Vohoses”,
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⇒ “2.2.2 Checking vacuum reservoir
ris
e
and vacuum hoses”, tee
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page 273 au
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ss
⇒ “2.2.3 Checking exhaust gas recirculation cooler changeover
ce
e
nl
pt
valve N345 and vacuum hoses”, page 274
du
an
itte
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erm
⇒ “2.2.4 Checking exhaust gas recirculation cooler changeover
ab
ility
valve”, page 275
ot p
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⇒ “2.2.5 Checking charge pressure control solenoid valve N75
h re
hole
and vacuum hoses”, page 276
spec
es, in part or in w
⇒ “2.2.6 Checking vacuum unit on turbocharger and vacuum ho‐
t to the co
ses”, page 277
2.1 Connection diagram - vacuum system
rrectness of i
l purpos
Caution
nform
ercia
Do not kink, twist or crush the vacuum lines when routing vac‐
uum lines. This may cause breakdowns.
m
at
om
ion
Push all hoses onto stop or at least 10 mm onto the respective
c
in t
or
connection. his
ate
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for
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Prote AG.
270 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Pressure canister
❑ On turbocharger.
❑ With position sender for gen AG
. Volkswagen AG
does
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charge pressure posi‐ yV
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tioner - G581- ris
ed b ara
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2 - Charge pressure control
sa
u ac
solenoid valve - N75- s
ce
le
un
pt
❑ Removing and installing
an
d
itte
⇒ page 242
y li
rm
ab
pe
ility
3 - Silencer
ot
wit
, is n
4 - Air filter
h re
hole
spec
5 - To brake servo
es, in part or in w
t to the co
6 - Connection piece
❑ On vacuum pump
rrectness of i
7 - Non-return valve
l purpos
❑ Observe installation po‐
sition
nform
ercia
8 - Exhaust gas recirculation
cooler changeover valve -
m
a
N345-
com
tion in
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9 - Cylinder head cover
thi
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en
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❑ For changeover for ex‐ C py
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haust gas recirculation rig ht
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2.2 Checking vacuum system
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-
2. Vacuum system 271
Caddy 2011 ➤ agen
AG. Volkswagen AG d
oes
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4-cylinder diesel engine
by
V (1.6 l engine, common rail) -oEdition
ol n t
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ara
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♦ Hand operated vacuum
au
th pump - VAS 6213- e or
ac
ss
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Do not kink, twist or crush the vacuum lines when routing vac‐
m
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uum lines. This may cause breakdowns.
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tion in
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Push all hoses onto stop or at least 10 mm onto the respective
te o
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connection.
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Test sequence
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– Pull off vacuum hose -2- from connection. Seal open end of
hose with suitable plug from engine bung set - VAS 6122- .
Note
Do not use screws or threaded bolts.
– Pull off vacuum hose -1- from connection.
– Connect hand vacuum pump - VAS 6213- to pulled-off end of
vacuum hose -1- and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Renew leaking vacuum hose or non-return valve.
If pressure does not drop:
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
If the non-return valve functions properly, a clear hiss is audible
when vacuum in vacuum hose is released.
– Reconnect vacuum hose to connecting piece and vacuum
pump.
272 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2.2 Checking vacuum reservoir and vacuum
hoses
Test sequence
– Pull off vacuum hose -arrow- from connection.
– Connect hand vacuum pump - VAS 6213- to removedenvacuum . Volkswagen AG
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hose -arrow- and generate a partial vacuum ofolk0.6
swa bar. does
no
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– Observe pressure gauge of hand vacuum ris pump - VAS 6213-
ed nte
for approx. 30 seconds. au
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• Vacuum must not drop.
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If vacuum drops:
itte
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– Pull off vacuum hose -2- from cylinder head cover -1-.
t to the co
– Seal open end of hose with suitable plug from engine bung set
- VAS 6122- .
rrectness of i
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Note
nform
Do not use screws or threaded bolts.
mercia
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– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
ion in
reservoir and generate a partial vacuum of 0.6 bar.
r
te o
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– Observe pressure gauge of hand vacuum pump - VAS 6213-
do
r
rp
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for approx. 30 seconds.
um
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• Vacuum must not drop.
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If vacuum drops: rig ht
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– Renew vacuum hose. cted agen
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If pressure does not drop:
– Connect hand vacuum pump - VAS 6213- with vacuum hose
from -VAS 6213- to cylinder head cover and generate a partial
vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Renew cylinder head cover ⇒ page 106 .
If pressure does not drop:
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
If the vacuum reservoir in the cylinder head cover works properly,
a hiss will be clearly audible when normal pressure is restored in
the vacuum hose.
– Reconnect vacuum hose to T-piece and cylinder head cover.
2. Vacuum system 273
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2.3 Checking exhaust gas recirculation
cooler changeover valve - N345- and
vacuum hoses
Test sequence
– Pull off vacuum hose -arrow- from connection.
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose -arrow- and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Unhook exhaust gas recirculation cooler changeover valve -
N345- from bracket on intake pipe.
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– Pull off vacuum hose -arrow- on bottom connection of exhaust d byV gu
ara
gas recirculation cooler changeover valve - N345- . orise nte
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– Seal open end of hose with suitable plug from engine
s bung set
s c
- VAS 6122- .
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Do not use screws or threaded bolts.
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es, in part or in w
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
t to the co
reservoir and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
rrectness of i
for approx. 30 seconds.
l purpos
• Vacuum must not drop.
If vacuum drops:
nform
ercia
– Renew vacuum hose.
m
a
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If pressure does not drop:
on in
r
te o
thi
– Connect hand vacuum pump - VAS 6213- with vacuum hose
s
iva
from -VAS 6213- to exhaust gas recirculation cooler change‐
do
r
rp
over valve - N345- and generate a partial vacuum of 0.6 bar.
um
fo
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ng
t.
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– Observe pressure gauge of hand vacuum pump - VAS 6213-
Co
op py
for approx. 30 seconds.
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• Vacuum must not drop. by c lksw
cted agen
Prote AG.
If vacuum drops:
– Renew exhaust gas recirculation cooler changeover valve -
N345- .
If pressure does not drop:
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
– Reconnect vacuum hose on T-piece and on exhaust gas re‐
circulation cooler changeover valve - N345- .
274 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2.4 Checking exhaust gas recirculation
cooler changeover valve
Test sequence
– Unhook exhaust gas recirculation cooler changeover valve -
N345- from bracket on intake pipe.
– Pull off vacuum hose -arrow- on middle connection of exhaust
gas recirculation cooler changeover valve - N345- .
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose -arrow- and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Raise vehicle on lift.
AG. Volkswagen AG d
agen oes
lksw not
– Pull off heat protectionby Vo
-2- from vacuum servo element.
gu
ara
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– Pull off vacuum
utho hose -1- from vacuum servo element. eo
ra
s a c
– Seal open s end of hose with suitable plug from engine bung set ce
e
nl
- VAS 6122- .
pt
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Note
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Do not use screws or threaded bolts.
hole
spec
es, in part or in w
t to the co
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum
reservoir and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
rrectness of i
for approx. 30 seconds.
l purpos
• Vacuum must not drop.
If vacuum drops:
nf
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orm
– Renew vacuum hose.
m
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n in
If pressure does not drop:
or c
thi
te
– Connect hand vacuum pump - VAS 6213- with vacuum hose
sd
iva
o
r
from -VAS 6213- to vacuum servo element of exhaust gas re‐
rp
cu
o
circulation cooler changeover valve and generate a partial
f
en
ng
t.
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vacuum of 0.6 bar.
Co
Cop py
t. rig
– Observe pressure gauge of hand vacuum pump - VAS 6213-
gh ht
pyri by
for approx. 30 seconds.
co Vo
by lksw
cted agen
Prote AG.
• Vacuum must not drop.
If vacuum drops:
– Renew exhaust gas recirculation cooler.
If pressure does not drop:
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
– Reconnect vacuum hose on exhaust gas recirculation cooler
and on exhaust gas recirculation cooler changeover valve -
N345- .
2. Vacuum system 275
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2.5 Checking charge pressure control sole‐
noid valve - N75- and vacuum hoses
Test sequence
– Press release buttons and remove hose -1- for venting crank‐
case.
– Unclip vacuum lines -arrows- and place to one side.
– Remove intake hose -3- on air filter.
– Unscrew bolt -2- (captive bolt). Twist intake hose -3- clockwise
out of its holder and remove it.
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– Pull off vacuum hose -arrow- on bottom connection of charge
Vol
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pressure control solenoid valve - N75- . ed
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– Seal open end of hose with suitable plug from engine
au
th bung set ra
- VAS 6122- . ss c
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Note
rm
ab
pe
ility
ot
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Do not use screws or threaded bolts.
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hole
spec
es, in part or in w
t to the co
– Pull off vacuum hose -arrow- from connection.
rrectness of i
– Connect hand vacuum pump - VAS 6213- to removed vacuum
l purpos
hose -arrow- and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
nform
ercia
for approx. 30 seconds.
m
a
• Vacuum must not drop.
com
tion in
If vacuum drops:
r
te o
thi
s
iva
– Renew vacuum hose.
do
r
rp
cum
fo
If pressure does not drop:
en
ng
t.
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op
– Connect hand vacuum pump - VAS 6213- with vacuum hose
C py
t. rig
gh
from -VAS 6213- to bottom connection of charge pressure
ht
pyri by
Vo
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control solenoid valve - N75- and generate a partial vacuum
c by lksw
cted agen
of 0.6 bar. Prote AG.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Renew charge pressure control solenoid valve - N75-
⇒ page 242 .
If pressure does not drop:
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
– Reconnect vacuum hose on T-piece and on charge pressure
control solenoid valve - N75- .
276 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– When fitting intake connecting pipe to turbocharger, ensure
that intake connecting pipe is correctly seated on stud of tur‐
bocharger. -arrow-.
2.2.6 Checking vacuum unit on turbocharger
and vacuum hoses
Test sequence
– Press release buttons and remove hose -1- for venting crank‐
case.
– Unclip vacuum lines -arrows- and place to one side.
– Remove intake hose -3- on air filter.
– Unscrew bolt -2- (captive bolt). Twist intake hose -3- clockwise
out of its holder and remove it.
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– Pull off vacuum hose -arrow- on middle connection of charge
d
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pressure control solenoid valve - N75- .
erm
ab
ility
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– Seal open end of hose with suitable plug from engine bung set
wit
is n
- VAS 6122- .
h re
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spec
urposes, in part or in wh
Note
t to the co
Do not use screws or threaded bolts.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
2. Vacuum system 277
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Open bracket -2- and unhook vacuum hose -1-.
– Pull off vacuum hose -1- from vacuum unit on turbocharger.
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose -arrow- and generate a partial vacuum of 0.6 bar.
– Observe pressure gauge of hand vacuum pump - VAS 6213-
for approx. 30 seconds.
• Vacuum must not drop.
n AG. Volkswagen AG do
wage
If vacuum drops: olks es n
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byV ua
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– Renew vacuum hose. ir se tee
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If pressure does not drop: ss
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nl
– Connect hand vacuum pump - VAS 6213- with vacuum hose
pt
du
an
itte
from -VAS 6213- to vacuum unit on turbocharger and generate
y li
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a partial vacuum of 0.6 bar.
ility
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– Observe pressure gauge of hand vacuum pump - VAS 6213-
wit
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for approx. 30 seconds.
hole
spec
• Vacuum must not drop.
es, in part or in w
t to the co
If vacuum drops:
– Replace turbocharger ⇒ page 237 .
rrectness of i
If pressure does not drop:
l purpos
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
– Reconnect vacuum hose on vacuum unit of turbocharger and
nf
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o
on charge pressure control solenoid valve - N75- .
rm
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atio
om
n in
c
– When fitting intake connecting pipe to turbocharger, ensure
or
thi
that intake connecting pipe is correctly seated on stud of tur‐
te
sd
iva
bocharger. -arrow-.
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
278 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3 Injectors/high-pressure accumulator
(rail)
⇒ “3.1 Overview - fuel return lines”, page 279
⇒ “3.2 Assembly overview - injectors”, page 280
⇒ “3.3 Removing and installing high-pressure lines”, page 280
⇒ “3.4 Removing and installing fuel rail”, page 286
⇒ “3.5 Removing and installing injectors”, page 290
⇒ “3.6 Adapting correction values for injectors”, page 295
⇒ “3.7 Replacing O-ring of fuel return lines”, page 296
⇒ “3.8 Check pressure retention valve in fuel return line”,
page 296
⇒ “3.9 Checking return flow rate of injectors at starter speed”,
page 298
⇒ “3.10 Testing injectors”, page 299
3.1 Overview - fuel return lines
1 - 0.5 bar fuel return line, low-
pressure fuel system
⇒ Item 1 (page 266)
❑ Flexible
❑ With pressure retention
valve
2 - 6.0 bar fuel return line, low-
pressure fuel system
⇒ Item 1 (page 266)
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❑ With pressure retention ir se
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valve utho
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3 - 0.5 bar fuel return lines, low-
ce
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nl
pressure fuel system
pt
du
an
itte
❑ Rigid.
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ab
ility
4 - 6.0 bar fuel return lines, low-
ot p
wit
pressure fuel system
, is n
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❑ Rigid.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Injectors/high-pressure accumulator (rail) 279
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3.2 Assembly overview - injectors
1 - Injectors
❑ Piezo injectors
WARNING
Only cleaning set - VAS
6811- may be used for
cleaning the sealing sur‐
face of the injector bore.
For detailed information
on how to use the clean‐
ing set as well as the or‐
der in which its compo‐
nents are applied, refer
to the ⇒ operating man‐
ual provided with the
cleaning set - VAS
6811- .
2 - Bolt
❑ Renew after removal
❑ 8 Nm +270° AG. Volkswagen AG d
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3 - High-pressure fitting d by Vo gu
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❑ Counterhold when loos‐ thor eo
ening the high-pressure s au ra
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lines. s
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un
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4 - Return lines retaining clip
an
d
itte
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❑ Renew after removal
ab
ility
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❑ Grease the retaining clip
wit
is n
lightly before installing
h re
ole,
the injector.
spec
urposes, in part or in wh
5 - Copper washer
t to the co
❑ Renew after removal
6 - O-ring
rrectne
❑ Renew after removal
❑ For renewing, use assembly sleeve - T10377-
ss o
cial p
f inform
mer
3.3 Removing and installing high-pressure
atio
om
lines
c
i
or
n thi
te
sd
a
⇒ “3.3.1 Removing high-pressure lines between fuel rail and in‐
iv
o
pr
jectors”, page 282
um
r
fo
en
ng
t.
yi
⇒ “3.3.2 Removing high-pressure line between fuel rail and high-
Co
op py
pressure pump”, page 283
t. C rig
gh ht
pyri by
Vo
⇒ “3.3.3 Installing high-pressure lines”, page 284
co lksw
by
cted agen
Prote AG.
Special tools and workshop equipment required
280 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
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ab
ility
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♦ Ratchet wrench - V.A.G 1331/1-
wit
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hole
spec
es, in part or in w
t to the co
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nf
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orm
m
atio
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or c
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♦ Tool insert 17 mm - V.A.G 1331/6-
te
sd
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Cop py
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♦ Engine bung set - VAS 6122-
3. Injectors/high-pressure accumulator (rail) 281
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Caddy 2011 ed➤
b ara
nte
ris
4-cylinderut
h diesel engine (1.6 l engine, common rail) - Edition
o eo
ra
07.2019
s a c
s
♦ Socket - T40055-
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Support sleeve - T10411-
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Vehicle diagnostic tester
3.3.1 Removing high-pressure lines between
fuel rail and injectors
– Remove engine cover panel ⇒ page 47 .
Caution
Ensure absolute cleanliness. There should be no dirt in the
disconnected fuel return lines or the open connections on the
injectors under any circumstances.
Protect open fuel connections from dirt entrainment using suit‐
able methods under all circumstances.
Used injectors may only be re-installed on the same cylinder.
Note
♦ The fluff-free cloth and the brake cleaner can be ordered in ⇒
ServiceNet; Workshop Equipment; Techno Equipment Cata‐
logue; BMK Consumables .
♦ Whenever work is done on the fuel system, ensure cleanliness
and do the work carefully. The fuel system reacts sensitively
to the ingress of dirt.
– Before removing, clean the parts thoroughly all over with brake
cleaner and fluff-free cloth.
Preferable order for disconnecting high-pressure lines cylinder
4-3-2-1
282 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– To disconnect the high-pressure lines, counterhold the high-
pressure fitting -A- on the injectors.
– Remove high-pressure line between fuel rail and injectors.
– Then only loosen the high-pressure line between fuel rail and
high-pressure pump -3-.
– Place removed parts on a clean, fluff-free surface and cover
them.
A clean plastic bag can also be used.
– Ensure that removed parts are not placed anywhere unpro‐
tected.
– Use a vacuum-type cleaner eto
n Aremove dirt
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high-pressure accumulator.
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– Seal all connections
or
ise with clean plugs from engine bungraset
nte -
VAS 6122- a. uth eo
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3.3.2 Removing high-pressure line between
un
pt
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fuel rail and high-pressure pump
erm
ab
ility
ot p
wit
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Caution
h re
ole,
spec
urposes, in part or in wh
Ensure absolute cleanliness. There should be no dirt in the
t to the co
disconnected fuel return lines or the open connections on the
injectors under any circumstances.
Protect open fuel connections from dirt entrainment using suit‐
rrectne
able methods under all circumstances.
s
Used injectors may only be re-installed on the same cylinder.
s o
cial p
f inform
mer
– Unscrew bolts -1 and 2-, and remove engine lifting eyes -3-.
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
3. Injectors/high-pressure accumulator (rail) 283
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew union nuts -1 and 4- and remove high-pressure line
-2-.
– Place removed parts on a clean, fluff-free surface and cover
them.
A clean plastic bag can also be used.
– Ensure that removed parts are not placed anywhere unpro‐
tected.
– Use a vacuum-type cleaner to remove dirt from taper seat on
high-pressure accumulator.
– Seal all connections with clean plugs from engine bung set -
VAS 6122- . . Volkswage AG n AG d
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3.3.3 Installing high-pressure lines
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Caution
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To position injection lines more easily and stress-free, loosen
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erm
ab
high pressure accumulator (rail) and injectors and shift slightly.
ility
ot p
The lines must never be bent or tensioned. Tension would oth‐
wit
is n
erwise cause the respective line to break in the long-term.
h re
ole,
spec
urposes, in part or in wh
t to the co
Note
rrectne
♦ Making use of a setting tool to adjust the high pressure or in‐
jectors (piezo injectors) is not permissible.
ss
♦ Observe cylinder-specific markings if reusing high-pressure
o
cial p
f
lines.
inform
mer
♦ The high-pressure lines may be re-used after the following
atio
m
checks:
o
n
c
i
or
n
♦ If the taper seal of respective high-pressure line has been
thi
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checked for deformation and cracks.
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♦ The inside of the line must be free of deformations, constric‐
en
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tions and damage.
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♦ Corroded lines should no longer be used.
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Caution
When installing a new short engine, it is compulsory to fix and
tighten the clamping jaws of the injectors to the specified torque
after installing the high-pressure lines ⇒ Item 20 (page 268) 20.
Clamping jaws are only secured »hand-tight« for setting the
injectors while installing high-pressure lines. Non-observance
of these notes may lead to damage to engine.
– Use a vacuum-type cleaner to remove dirt from taper seat on
high-pressure accumulator.
– Clean fuel line and line head using cold cleaning solvent.
– Moisten union nut thread with fuel.
– Fit the injection lines from high-pressure accumulator to injec‐
tor by hand first, only tighten union nuts by hand.
– Then, install high-pressure line from high-pressure pump to
high-pressure accumulator.
284 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– To install high-pressure line between high-pressure pump and
high-pressure accumulator, slide support sleeve -T10411- on‐
to fuel pressure sender - G 247- .
Note
♦ The lifting eye (for engine mounting) must be movable in order
to fit union nut on high-pressure pump; loosen bolts -4- to do
this.
♦ Support sleeve -T10411- specifies the correct distance be‐
tween fuel pressure sender - G 247- and high-pressure line.
G. Volkswagen
– Only tighten union nuts on wage
nA
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from
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sure pump to high-pressure accumulator by hand. ot g
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The further final assembly
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Sequence ss
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– Tighten high-pressure lines on high-pressure accumulator and
y li
erm
ab
injector to specified torque ⇒ Item 16 (page 267) 16.
ility
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wit
– To tighten injector lines, use torque wrench - V.A.G 1331- with
, is n
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ratchet - V.A.G 1331/1- and 17 mm socket - T40055- .
hole
spec
– Tighten high pressure line -2- between high pressure pump
es, in part or in w
t to the co
and high pressure accumulator first at high pressure pump
-4- and then at high pressure accumulator -1-.
rrectness of i
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Prote AG.
3. Injectors/high-pressure accumulator (rail) 285
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Tighten bolt -3- for retainer for high-pressure line.
Specified torques
♦ ⇒ page 280
♦ ⇒ page 265
♦ Firmly screw lifting eye in ⇒ page 53 .
– Remove support sleeve - T10411- .
– Reconnect connector to fuel pressure sender - G247- .
– Press return line connections carefully onto injectors (check
seal for damage before connecting return line). You should
hear them click into place.
– Engage pressure retention valve in retainer provided on the
cylinder head cover.
– Bleed fuel system with ⇒ Vehicle diagnostic tester.
Note
♦ After renewing the injectors, “perform adaptation of the cor‐
rection values” ⇒ Vehicle diagnostic tester. When doing this,
AG. Volkswagen AG d
select “Reading / adapting” correction values. lksw
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♦ Never allow the high-pressure pump to run dry under iany
se cir‐
db ua
ran
cumstances. If the low-pressure section of the fuel system
ut
ho
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was tee
or
also opened (between fuel tank and high pressure ss apump), the ac
fuel system must be filled ⇒ page 268 .
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– Filling fuel system ⇒ page 268 .
erm
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– Check high pressure lines and connections for leaks. To do
wit
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this, allow engine to run at idle for several minutes without
h re
pressing accelerator pedal.
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– Switch off ignition.
t to the co
– Check the complete fuel system and return line connections
for leaks.
rrectness of i
– Wipe the connections with a clean cloth and check whether
there is fuel on the cloth.
l purpos
• Renew the affected component if leakage still occurs after
tightening to the correct torque.
nform
mercia
• Tightening threaded connections further is not permissible.
at
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ion
c
– Then test drive the vehicle, accelerating to full throttle at least
in t
or
once.
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ate
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– Then check high-pressure section of fuel system again for
um
for
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If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Switch off engine and
clear event memory ⇒ Vehicle diagnostic tester. Then continue
with a road test.
3.4 Removing and installing fuel rail
Special tools and workshop equipment required
286 Rep. gr.23 - Mixture preparation - injection
AG. Volkswagen AG d
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byV gu
ara
4-cylinderrisdiesel engine (1.6 l engine, common rail)
ed
nte- Edition 07.2019
tho eo
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♦ Pliers - 3314- ss c
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itte
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erm
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ility
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ole,
spec
urposes, in part or in wh
t to the co
rrectness
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
o
cial p
f inform
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atio
om
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Prote AG.
♦ Ratchet wrench - V.A.G 1331/1-
♦ Tool insert 17 mm - V.A.G 1331/6-
3. Injectors/high-pressure accumulator (rail) 287
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Socket - T40055- n AG. Volkswagen AG do
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♦ Engine bung set - VAS 6122-
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♦ Vehicle diagnostic tester
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WARNING
If the fuel pressure regulating valve - N276- has been renewed,
the learnt values for the fuel system must be reset ⇒ Vehicle
diagnostic tester.
WARNING
♦ Read rules for cleanliness and the instructions for working
on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
– Remove fuel high-pressure line -2- ⇒ page 280 .
288 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
In order to undo the union nuts on the high-pressure pump, the
lifting eye must be movable. To ensure this, loosen the bolts -4-.
– Open cable guide catches -arrows- to lay wiring harness to
side.
Caution
Make sure that no wiring connections are damaged when dis‐
connecting the connectors. Otherwise the whole wiring har‐
ness will need to be renewed. Do not compress the pliers -
3314- to firmly to separate the connectors, otherwise the n AG. Volkswagen AG do
support sleeve may be damaged. olks
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– Position pliers - 3314- with groove -arrow A- on support sleeve
un
pt
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shoulder -arrow B-.
itte
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spec
urposes, in part or in wh
t to the co
rrectness o
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– Carefully pull connectors off glow plugs in
inform
-direction of arrow-.
mer
atio
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Prote AG.
3. Injectors/high-pressure accumulator (rail) 289
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull off electrical connectors -1 and 4-.
– Pull off fuel return hose -2-.
– Detach electrical connectors -1-, -6- and -7-.
Caution
♦ Mark high-pressure lines to indicate which ones belong to
which cylinders. Injectors must always be re-installed on
the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system.
♦ The open connections must be sealed immediately with a
suitable cap. AG. Volkswagen AG d
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– Remove high pressure lines between injectors (piezohoris
injec‐ nte
eo
tors) and high pressure accumulator ⇒ page 280 aut. ra
ss c
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Note
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In order to release the high-pressure lines, use the connecting
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piece -A- as a counterhold.
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– Place the removed high-pressure lines on a clean fluff-free
t to the co
cloth.
rrectness of i
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– Remove high pressure accumulator. To do this, unscrew the
two bolts -arrows-.
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Installing
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Install in reverse order of removal, observing the following:
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• It must be possible to move the rail so the hoses can be fitted
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Specified torques
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
co lksw
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♦ ⇒ “3.2 Assembly overview - injectors”, page 280
3.5 Removing and installing injectors
290 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Special tools and workshop
equipment required
n AG. Volkswagen AG do
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urposes, in part or in wh
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♦ Puller - T10055-
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f in
♦ Assembly sleeve - T10377-
form
mer
atio
♦ Socket - T40055-
om
n
c
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
or
n thi
te
sd
va
♦ Ratchet wrench - V.A.G 1331/1-
i
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♦ Support sleeve - T10411-
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♦ Injector remover - T10402-
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Prote AG.
3. Injectors/high-pressure accumulator (rail) 291
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Mouldings and trims; Removing and
installing plenum chamber cover
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Plenum chamber bulkhead .
WARNING
♦ Read through the rules for cleanliness and the instructions
for working on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
– Disconnect connectors -1- from injectors to be removed.
– Unscrew high pressure line between fuel rail and injectors
⇒ page 280 .
– To disconnect the high-pressure lines, counterhold the high-
pressure fitting -A- on the injectors.agen AG. Volkswagen AG do
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Caution ho
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Maintain cleanliness.s It must be ensured that no dirt gets into
ce
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the disconnected fuel return lines or the open connections of
un
pt
an
d
the injectors (Piezo injectors).
itte
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erm
ab
Protect open fuel connections from dirt entrainment using suit‐
ility
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able methods under all circumstances.
wit
is n
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ole,
Used injectors (piezo injectors) may be re-installed only on the
spec
same cylinder from which they were removed.
urposes, in part or in wh
t to the co
– Only loosen high pressure line on high pressure accumulator
rrectne
-3- and high pressure pump -1-.
ss o
cial p
Note
inform
mer
♦ Open the return line connection with a narrow screwdriver and
atio
m
long-nosed pliers.
o
n
c
i
or
n thi
♦ Renew clips.
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Prote AG.
292 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– To release fuel return line, pull clip out in direction of arrow.
– Pull fuel return line connections off injectors in
-direction of arrow-.
Note
AG. Volkswagen AG d
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♦ One clamping piece always secures two injectors and can only
Vol
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not
be removed if both injectors are removed. ed
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♦ Sequence for removing injectors: first remove injectorut
h
for cyl‐ ra
sa
inder 2, then for cylinder 1/cylinder 4, and then sfor cylinder 3. c
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– Unscrew bolt for clamping piece.
itte
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ility
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– Fit puller - T10055- with injector puller - T10402- -1-.
wit
, is n
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– Detach injector by tapping with puller - T10055- .
hole
spec
– Repeat process at second injector.
es, in part or in w
t to the co
– Remove clamping piece with injectors.
rrectness of i
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mercia
at
om
ion
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or
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ate
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cum
for
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Cop py
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cted agen
Prote AG.
3. Injectors/high-pressure accumulator (rail) 293
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Installing
Install in reverse order of removal, observing the following:
If a used injector is being re-installed:
– Clean injector tip and sealing surface.
– To remove the old copper seal from the injector, carefully
clamp the copper seal in a pair of pliers so the copper seal is
just prevented from spinning. Then carefully pull and twist the
injector out of the copper seal by hand.
– Clean injector tip and sealing surface.
– Fit new copper sealing ring -1- on injector -2- with help of as‐
sembly sleeve - T10377- . Use “narrow” side of assembly
sleeve - T10377- for this.
Note
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
– Carefully slide new O-ring over fuel return connection to avoid
damaging O-ring.
– Clean sealing surface of injector in cylinder head and injector
shaft.
WARNING AG. Volkswagen AG d
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olksw not
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d
Only cleaning set - VAS 6811- may oris be used for cleaning the
e nte
eo
sealing surface of the injector bore.
aut
h
ra
ss c
For detailed information on how to use the cleaning set as well
ce
le
un
pt
as the order in which its components are applied, refer to the
an
d
itte
⇒ operating manual provided with the cleaning set - VAS
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rm
ab
6811- .
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spec
– Renew seal -1- for injector bore using assembly sleeve -
es, in part or in w
T10377- .
t to the co
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a
com
tion in
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te o
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iva
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ng
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Cop py
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by lksw
cted agen
Prote AG.
294 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fit clips before fitting the injector. To do this, grease lightly.
• Ensure that the injector bore is clean before fitting.
– Slide clamping piece onto injectors (piezo injectors). When
doing so, note the installation position ⇒ page 280 .
– Always carefully insert 2 injectors with clamping piece into in‐
jector bores in cylinder head.
Caution
You must therefore proceed very carefully in order to avoid
unnecessary assembly work or further damage.
Avoid damage to the injectors and prevent them coming into
contact with the cylinder head.
It should be possible to align the injectors while fitting the high-
pressure lines by hand.
– Tighten bolts initially to no more than 1 - 2 Nm.
After renewing an injector, the adaptation value must be written
into the engine control unit.
In addition, check for all other injector units that the values from
the “adaptation for injectors” are stored in the engine control unit.
Do not attempt to re-enter these values if the correct values are
already stored in the engine control unit.
The adaption procedure ⇒ page 295 is described in ⇒ Vehicle
diagnostic tester.
– Install high-pressure lines ⇒ page 280 .
Specified torques
♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
3.6 Adapting correction values
swa
gen AGfor injectors
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does
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The function “Adaptation of injectors”
se
d b serves to correct the injec‐
y ara
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tion rates for each cylinder ofthaoricommon rail system individually eo
across the entire ignition map
s a range.
u ra
c
s
ce
le
The 6-digit adaptation value -1- (details in illustration are for ex‐
un
pt
ample only) are marked separately on each injector. The marked
an
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values may consist of letters and/or numbers.
erm
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1- Adaptation value
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2- Part number
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urposes, in part or in wh
After renewing an injector, the adaptation value must be written
t to the co
into the engine control unit.
After renewing the engine control unit, the “adaptation values for
the injectors” must be transferred to the new engine control unit.
rrectne
The work procedure for the adaptation is described in ⇒ Vehicle
s
diagnostic tester.
s o
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f i
In addition, check for all other injector units that the values from
nform
the “adaptation for injectors” are stored in the engine control unit.
mer
Do not attempt to re-enter these values if the correct values are
atio
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already stored in the engine control unit.
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agen
Prote AG.
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3.7 Replacing O-ring of fuel return lines
Removing
Proceed with extreme caution. Avoid damage to fuel return line.
– Lever old O-ring very carefully off fuel return line.
Do not work with a sharp-edged tool.
Installing
Install in reverse order of removal, observing the following:
Note
Avoid any rolling movement when pushing O-rings on. The O-
rings must be free of twists in their seats in fuel return line.
Proceed with extreme caution. Avoid damage to the O-ring and
fuel return line.
– Clean seating surfaces for O-rings on fuel return line very
thoroughly.
– Carefully push O-ring -1- onto its seat -2-.
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3.8 Check pressure retention valve in fuel utho tee
or
return line
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pt
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Special tools and workshop equipment required
an
itte
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erm
ab
♦ Pressure gauge - VAS 6330-
ility
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♦ Adapter - VAS 6330/3-1-
on
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or
♦ Adapter - VAS 6330/3-2-
his
ate
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The pressure retention valve has the task of maintaining a resid‐
p
cum
for
ual pressure (control volume) of approx. 1 bar in the return lines.
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This residual pressure is required for the control function of the
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Prote AG.
296 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
WARNING
n AG. Volkswagen AG
♦ Read rules for cleanliness
olks
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does for working
not
on the fuel system
d by V ⇒ page 8 . gu
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ris
♦ Always au
thfollow
o
these rules for cleanliness and instructions
eo
ra
before
s starting work and while working on the fuel system.
s c
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itte
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– Clean return line connection from first cylinder (e.g. with de‐
erm
ab
greaser) before removing.
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– Dry return line connection of first cylinder.
h re
hole
spec
– Cover return line connection of first cylinder with a clean lint-
es, in part or in w
free cloth.
t to the co
– Pull return line connection off first cylinder. To do so, pull out
release clip -arrow-.
rrectness of i
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Note
nform
♦ Open return line connection with a narrow screwdriver and
ercia
long-nosed pliers.
m
at
om
io
♦ Maintain cleanliness. No dirt must be allowed to get into the
n
c
in t
disconnected fuel return lines or the open connections on the
or
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e
injectors (piezo injectors).
at
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♦ Always renew clip.
for
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ng
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– Install tester for fuel return system - 6330- with adapters -VAS
6330/3-1- and -VAS 6330/3-2- between return line connection
on injector and return line.
– Start engine.
– Check pressure on pressure gauge.
♦ Specification: approx. 1.0 bar
If the specification is not reached, replace the pressure retention
valve.
After any work on the fuel system
• Observe instructions for working on fuel system ⇒ page 5 .
3. Injectors/high-pressure accumulator (rail) 297
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
3.9 Checking return flow rate of injectors at
starter speed
Note
♦ Leaky regulating valves in injectors may lead to irregular en‐
gine running or may prevent engine from starting.
♦ To check regulating valves for soiling and related higher leak‐
age, in addition to the "classical" return quantity measurement,
checking with vacuum is also possible.
♦ Observe instructions for working on fuel system ⇒ page 5 .
Sequence of operations
– Open return line connection -3- of injectors on fuel return pipe
using a narrow blade screwdriver and long-nose pliers.
– Collect escaping fuel with a cleaning cloth.
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0.5 bar low pressure fuel system:
spec
urposes, in part or in wh
– Seal open return line connection with a blanking plug
t to the co
-arrow-.
rrectness o
cial p
f inform
mer
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298 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
n AG. Volkswagen AG do
6.0 bar low pressure fuel system: lkswage es n
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– Seal open return line connection ir se with a blanking plug
d b ran
tee
-arrow-. utho
or
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ss
Continuation all vehicles
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– Measure at turnover speed ≥ 230 rpm during engine start.
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• Specification: return volume 0 ml
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• Droplets are allowed
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• If a flow rate can be measured, at least one of the injectors is
spec
defective.
es, in part or in w
t to the co
– Check injectors with vacuum ⇒ page 299 .
rrectness of i
3.10 Testing injectors
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Note
nf
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♦ Leaky regulating valves in injectors may lead to irregular en‐
m
atio
m
gine running or may prevent engine from starting.
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♦ To check regulating valves for soiling and related higher leak‐
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age, in addition to the "classical" return quantity measurement,
iv
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checking with vacuum is also possible.
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♦ Observe instructions for working on fuel system ⇒ page 5 .
Co
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Special tools and workshop equipment required
cop Vo
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♦ Hand operated vacuum pump - VAS 6213-
♦ Locally manufacture an -adapter- from a return line.
3. Injectors/high-pressure accumulator (rail) 299
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
– Collect escaping fuel with a cleaning cloth.
– Open cleaned return line connection of injector to be tested
using a narrow blade screwdriver and long-nosed pliers.
Always renew clips.
– Pull off return line in direction of arrow.
AG. Volkswagen AG d
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WARNING by Vol
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♦ The fuel and the fuel lines in the fuel system can becomeauth
ra
very hot (danger of scalding)! ss c
ce
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un
pt
♦ The fuel system is also under pressure! Before opening
an
d
itte
the system, place a cloth around the connection and re‐
y li
rm
ab
duce pressure by carefully loosening the connection!
pe
ility
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♦ Wear eye and hand protection when performing any type
, is n
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of repair work on the fuel system!
hole
spec
es, in part or in w
t to the co
– Undo fuel high-pressure line -2-. To do this, only undo union
nuts on high-pressure accumulator -1-.
rrectness of i
– Connect clean, blown-out adapter to injector to be tested.
l purpos
nform
mercia
a
com
tion in
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op py
– Use hand vacuum pump - VAS 6213- to generate vacuum of
t. C rig
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approx. -500 mbar. p by
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If injectors are OK, pressure remains constant for 30 seconds. Prote AG.
If injectors are defective, the pressure drops back to 0 bar within
2 to 3 seconds.
Repeat check is necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew injectors ⇒ page 290 .
300 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 High-pressure pump
⇒ “4.1 Assembly overview - high-pressure pump”, page 301
⇒ “4.2 Removing and installing high-pressure pump”, page 302
⇒ “4.3 Pressure testing high-pressure pump”, page 306
⇒ “4.4 Checking high-pressure pump”, page 308
4.1 Assembly overview - high-pressure pump
1 - High-pressure pump
❑ Removing and installing
⇒ page 302
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⇒ page 58 ut
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3 - Bolts s
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❑ Renew after removal
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❑ 20 Nm +180°
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4 - Bolt
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❑ Renew after removal
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❑ 20 Nm +45°
t to the co
5 - Nut
❑ 95 Nm
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6 - Crankshaft
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7 - Hub
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8 - Bolt
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❑ Renew after removal
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❑ 20 Nm +45°
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9 - Bolt
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❑ 20 Nm
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Cop py
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Prote AG.
4. High-pressure pump 301
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4.2 Removing and installing high-pressure pump
Special tools and workshop
equipment required
AG. Volkswagen AG d
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du
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es, in part or in w
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♦ Counter-hold tool - T10051-
or
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♦ Puller - T40064-
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♦ Thrust piece - T40064/1-
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- C py
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♦ Pliers - 3314-
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Prote AG.
302 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
Caution
♦ Observe rules for cleanliness and the instructions for
working on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
Risk of irreparable damage to high-pressure pump if allowed
to run dry.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. Do not run the high-pressure pump
while empty. Initial fuel filling ⇒ page 268 .
♦ Protect open fuel connections from dirt entrainment using
suitable methods under all circumstances.
– Remove toothed belt from camshaft and high-pressure pump
⇒ page 127 .
Caution
Make sure that no wiring connections are damaged when dis‐
connecting the connectors. Otherwise the whole wiring har‐
ness will need to be renewed. Do not compress the pliers -
3314- to firmly to separate the connectors, otherwise the
support sleeve may be damaged.
– Position pliers - 3314- with groove -arrow A- on support sleeve
shoulder -arrow B-.
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ility
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– Carefully pull connectors off glow plugs in
h re
-direction of arrow-.
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
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n thi
te
sd
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fo
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Cop py
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303
cted agen
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4. High-pressure pump
AG.
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Detach connector -1- of fuel temperature sender - G81- .
– Unscrew securing bolt -arrows-. Lay coolant return line to side.
AG. Volkswagen AG d
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– Unscrew bolts -arrows-.
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pt
du
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itte
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ility
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, is n
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spec
es, in part or in w
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– Pull fuel supply line -arrow- off high-pressure pump.
nf
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orm
m
atio
om
n in
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sd
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f
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Cop py
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by lksw
cted agen
Prote AG.
304 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -1-, -3- and -4-. Detach connector -arrow- of fuel
metering valve - N290- . gen AG
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d wa oes
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– Pull off fuel return line -2-. byV gu
ara
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ris
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ss
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pt
du
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itte
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ility
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– Unscrew bolts -4- and then remove bracket.
rrectness of i
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– Remove high-pressure fuel line between high-pressure pump
yi Co
op py
and high-pressure accumulator ⇒ Item 12 (page 267) . t. C rig
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– Remove toothed belt pulley from high-pressure pump.
co Vo
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Prote AG.
– Hold hub of high-pressure pump with the counterhold -
T10051- and undo the nut -1-.
4. High-pressure pump 305
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Position puller - T40064- with thrust piece - T40064/1- and pin
- T40064/2- as shown and pull hub off high-pressure pump. If
necessary, use an open-ended spanner, width across flats 24
mm, for counterholding.
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– Unscrew boltsuth-arrows- of high-pressure pump.
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ra
s a c
– Remove high-pressure pump. s
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nl
pt
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Installing
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itte
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Install in reverse order of removal, observing the following:
ility
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After any work on the fuel system
, is n
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hole
• Observe instructions for working on fuel system ⇒ page 5 .
spec
es, in part or in w
– Read event memory and, if necessary, delete event memory
t to the co
entry ⇒ Vehicle diagnostic tester.
– Filling/bleeding high-pressure pump/fuel system ⇒ page 268 .
Specified torques rrectness of i
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♦ ⇒ “4.1 Assembly overview - high-pressure pump”, page 301
nf
ercia
♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
orm
m
♦ ⇒ “3.1 Assembly overview - toothed belt drive”, page 125
atio
om
n in
or c
thi
4.3 Pressure testing high-pressure pump
te
sd
iva
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Special tools and workshop equipment required
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m
f
en
ng
t.
yi Co
♦ Hand operated vacuum pump - VAS 6213- . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
306 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Make an -adapter- from a high-pressure line.
♦ During further work, this carefully cleaned adapter is to be
connected to the high-pressure connection on the high-pres‐
sure pump, free of tension.
• Tests on fuel low-pressure side have been performed and
were not cause for complaint.
• Fuel tank is filled with clean fuel.
• Starter motor turns at starting speed ≥ 230 rpm ⇒ Electrical
system; Rep. gr. 27
• Observe safety precautions ⇒ page 1 .
• Comply with rules for cleanliness ⇒ page 8
• Observe instructions for working on fuel system ⇒ page 5
Sequence of operations
– Remove high-pressure fuel line -2- between high-pressure
pump and high-pressure accumulator ⇒ Item 12 (page 267) .
AG. Volkswagen AG d
agen oes
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un
pt
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d
itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
4. High-pressure pump 307
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Connect thoroughly clean, locally made adapter to high-pres‐
sure connection of high-pressure pump.
– Connect hand vacuum pump - VAS 6213- to custom-made
adapter.
– Use hand vacuum pump - VAS 6213- to generate at least 1
bar pressure.
If high-pressure pump is OK, pressure should stay constant for
more than 30 seconds.
If high-pressure pump is defective, the pressure drops back to 0
bar within 2 to 3 seconds. agen
AG. Volkswagen AG d
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Repeat check is necessary, observe
ed
by
V
pressure loss at hand-oper‐t guara
ated vacuum pump - VASho6213- .
ris nte
e t or
au ac
– Renew high-pressure
ss pump ⇒ page 302 .
ce
e
nl
Specified torques
pt
du
an
itte
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
erm
ab
ility
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Component Specified torque
wit
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Adapter 20 Nm
hole
spec
es, in part or in w
t to the co
4.4 Checking high-pressure pump
Special tools and workshop equipment required
rrectness of i
♦ Torque wrench - V.A.G 1331-
l purpos
nf
ercia
orm
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om
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thi
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t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.
♦ Socket - T40055-
308 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
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♦ High-pressure pump tester
rised - VAS 6683- ara
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un
pt
an
d
itte
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erm
ab
ility
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is n
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ole,
spec
urposes, in part or in wh
t to the co
rrectne
Sequence of operations
s
– Remove engine cover panel ⇒ page 47 .
s o
cial p
– Extract dirt from taper seat of union nuts, clean fuel line and f inform
mer
line head before removal using cold cleaning solvent and dry
atio
off with compressed air.
om
n
c
i
or
n thi
e
WARNING
t
sd
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pr
cum
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fo
The fuel system is pressurised.
en
ng
t.
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op
♦ Danger of injury through fuel spray. C py
t. rig
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• Wear protective goggles.
op Vo
by c lksw
cted agen
Prote
• Wear protective gloves.
AG.
• To release pressure, wrap a clean cloth around the con‐
nection and carefully loosen the connection.
4. High-pressure pump 309
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew union nut -2- from no. 1 cylinder.
– Loosen union nut -4- on fuel rail 2 turns.
– Hold high-pressure line -1- in high-pressure pump tester - VAS
6683- -3-.
– Install union nut -4- on fuel rail and tighten by hand.
– Tighten union nuts -4-.
– Seal open connections using clean plugs from engine bung
set - VAS 6122- .
– Disconnect all 4 connectors of injectors.
– Have a second mechanic start the engine.
• Fuel must be supplied to the high-pressure pump tester - VAS
6683- .
Installing
Install in reverse order of removal, observing the following:
Note
♦ Observe cylinder-specific markings if reusing high-pressure
lines.
♦ The high-pressure lines may be re-used after the following
checks:
♦ Check taper seal of respective high-pressure line for defor‐
mation and cracks.
♦ The inside of the line must be free of deformations, constric‐
tions and damage. AG. Volkswagen AG d
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♦ Corroded lines should no longer be used. ol not
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– Checking fuel system for leaks ⇒ page 268 . s au ra
c
s
ce
Specified torques
le
un
pt
an
d
itte
♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
y li
rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
310 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 311
⇒ “5.2 Removing and installing intake manifold”, page 312
⇒ “5.3 Removing and installing throttle valve module GX3 ”, page
316
5.1 Assembly overview - intake manifold
1 - Guide tube AG. Volkswagen AG d
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❑ for oil dipstick olksw not
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2 - Seal rise nte
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❑ Renew after removal ss a c
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3 - Seal
pt
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itte
❑ Renew after removal
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ility
4 - Bolt
ot p
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❑ 8 Nm
h re
hole
spec
5 - Fuel return line
es, in part or in w
t to the co
6 - Coolant line
7 - Bolt
rrectness of i
❑ 9 Nm
l purpos
8 - Bolt
❑ 9 Nm
nform
ercia
9 - Intake manifold
m
at
❑ Removing and installing
om
io
⇒ page 312
n
c
in t
or
his
e
10 - Bolt
at
do
priv
c
❑ 9 Nm
um
for
en
ng
t.
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11 - Bracket
Co
Cop py
t.
❑ For exhaust gas recircu‐
rig
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lation cooler change‐ cop Vo
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over valve - N345- . cted agen
Prote AG.
12 - Bolt
❑ 9 Nm
13 - Exhaust gas recirculation
cooler changeover valve -
N345-
14 - Seal
❑ Renew after removal
15 - Connecting pipe
❑ To exhaust gas recirculation cooler
❑ Install so that component is not under tension
16 - Bolt
❑ 20 Nm
17 - Clip
❑ Renew after removal
❑ 5 Nm
5. Intake manifold 311
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
18 - Connection
❑ For exhaust gas recirculation
19 - Bolt
❑ 8 Nm
20 - Seal
❑ Renew after removal
21 - Throttle valve module - GX3-
❑ Removing and installing ⇒ page 316
22 - Bolt
❑ 8 Nm
23 - Bolt
❑ 9 Nm
24 - Clip
5.2 Removing and installing intake manifold
Special tools and workshop equipment required
♦ Pliers - 3314-
AG. Volkswagen AG d
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♦ Torque wrench - V.A.G 1410-
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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by lksw
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Prote AG.
312 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Hexagon key - T10405-
Removing
WARNING
♦ Read through the rules for cleanliness and the instructions
for working on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
– Open cable guide catch -arrows- to lay wiring harness to side.
Caution AG. Volkswagen AG d
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Make sure that no wiring connections are damagedsedwhen by
dis‐ gu
ara
connecting the connectors. Otherwise the whole thori wiring har‐ nte
eo
ness will need to be renewed. Do not compress
s au the pliers - ra
c
3314- too firmly to separate the connectors, otherwise the
s
ce
e
support sleeve may be damaged.
nl
pt
du
an
itte
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erm
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ility
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wit
, is n
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hole
spec
– Position pliers - 3314- with groove -arrow A- on support sleeve
es, in part or in w
shoulder -arrow B- and pull connectors off glow plugs.
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
5. Intake manifold 313
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Carefully pull connector off glow plug in -direction of arrow-.
– Unclip vacuum lines -1- and -2-.
– Pull catch to one side -arrow- and pull off exhaust gas recir‐
culation cooler changeover valve - N345- -3- downwards AG. Volkswagen AG d
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place to one side. by
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pe
ility
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, is n
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spec
– Unscrew bolts -arrows- and place coolant return line to one
es, in part or in w
t to the co
side
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
cum
– Unscrew bolts -arrows-.
fo
en
ng
t.
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Removing high-pressure accumulator ⇒ page 286 . t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
314 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull connector -2- off throttle valve module - GX3- .
– Remove bolt -3- from dipstick connection.
Instructions for hose connections ⇒ page 246
– Remove charge air hose -2- between throttle valve module -
GX3- and charge air pipe.
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– Remove exhaust gas recirculation connecting pipe. Open clip
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-1-.
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spec
urposes, in part or in wh
t to the co
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5. Intake manifold 315
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen
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– Unscrew bolts -arrows- for intake manifold
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outside to inside using socket T30ho-risT10405- . tee
t or
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– Carefully remove intake manifold.
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Install in reverse order of removal, observing the following:
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Renew seals.
t to the co
– Tighten intake manifold bolts from inside out in diagonal se‐
quence.
rrectness of i
– Install exhaust gas recirculation pipe free of stress. To achieve
l purpos
this, start all bolts hand-tight first, and tighten them diagonally
and alternately after.
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Specified torques
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♦ ⇒ “5.1 Assembly overview - intake manifold”, page 311
on
c
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or
♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
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5.3 Removing and installing throttle valve
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module - GX3- Cop py
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Special tools and workshop equipment required
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♦ Torque wrench - V.A.G 1410-
Removing
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
Instructions for hose connections ⇒ page 246
– Loosen hose clamps -1- and -2- and remove air hose.
316 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -arrows-.
– Free off coolant hose -3-.
– Release hose clip -2-.
– Disconnect electrical connector -1- on charge pressure sender
- G31- and remove air pipe.
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– Disconnect electrical connector -2-. byV
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– Remove bolt -1- for dipstickutguide
ho tube. or
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– Unscrew bolts -arrows- and remove throttle valve module -
s
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GX3- .
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Install in reverse order of removal, observing the following:
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Specified torques
hole
spec
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 311
es, in part or in w
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5. Intake manifold 317
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
6 Air filter
⇒ “6.1 Assembly overview - air filter housing”, page 318
⇒ “6.2 Removing and installing air filter housing”, page 319
6.1 Assembly overview - air filter housing
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❑ Removing and installing
spec
⇒ page 323
es, in part or in w
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5 - O-ring
❑ Renew after removal
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❑ Install with silicone-free
lubricant
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6 - Bolt
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❑ 1.5 Nm
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7 - Bolt
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❑ 8 Nm
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❑ Remove dirt, leaves and
AG.
salt residues
11 - Air filter element
❑ Always use Genuine
Part for air filter element
❑ Observe change inter‐
vals ⇒ Maintenance ; Booklet 39
12 - Air filter lower part
❑ Remove dirt, leaves and salt residues
❑ For cold countries, an air filter lower part is installed with a hose for hot air intake.
❑ Country-specific version: With snow screen.
13 - Connection for water drain hose
❑ Cleaning
14 - Water drain hose
❑ Cleaning
15 - Flutter valve
❑ Cleaning and reinstalling.
318 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
16 - Intake air guide
❑ To lock carrier.
❑ Remove dirt, leaves and salt residues
17 - Spring-type clip
18 - Connection hose
❑ To turbocharger
6.2 Removing and installing air filter hous‐
ing
Removing
– Open air intake cover. To do this, carefully release the catches
-arrows-.
– Unscrew bolts -arrows- for air intake -1- and take connecting
hose -2- out of guide.
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– Press in locking lugs -1- and -3- and pull connecting hose -4-
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off air filter housing -2-.
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6. Air filter 319
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Detach connector from air mass meter - G70- -1- and pull off
vacuum line -2-.
– Loosen threaded connection at air filter housing -3-. AG. Volkswagen AG d
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– Open clip -4- and pull off hose leading to turbocharger. d by V gu
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– Remove entire air filter housing. utho eo
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– Remove water drain hose -arrow- from lower part of air filter.
Remove dirt and leaves from the connection and the hose. es, in part or in w
t to the co
Remove suction hose
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Note
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As it is difficult to gain access to clip on suction hose, it is better
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to remove intake connecting pipe from turbocharger.
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– Remove crankcase breather hose -1-.
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– Pull vacuum hoses -arrows- off suction hose -3-, remove and
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– Completely unscrew bolt -2- (make sure bolt is captive).
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– Swing intake union to the right and remove with suction hose
-3-.
Install suction hose
– When fitting intake connecting pipe to turbocharger, ensure
that intake connecting pipe is correctly seated on stud of tur‐
bocharger. -arrow-.
Installing
Install in reverse order of removal. During this procedure, observe
the following:
Note
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Use a silicone-free lubricant to install the air hose.
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic parts catalogue (ETKA) .
Specified torques
♦ ⇒ “2.1 Assembly overview - charge air system”, page 245
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
320 Rep. gr.23 - Mixture preparation - injection
AG. Volkswagen AG d Caddy 2011 ➤
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⇒ “7.1 Removing and installing Lambda probe G39 ”, page 321
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7.1 Removing and installing Lambda probe
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- G39-
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Special tools and workshop equipment required
spec
es, in part or in w
♦ Lambda probe open ring spanner set - 3337-
t to the co
rrectness of i
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♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
t.
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Removing
– Disconnect electrical connector -arrow- for Lambda probe -
G39- .
7. Lambda probe 321
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew Lambda probe - G39- -3-, using tool from Lambda
probe open ring spanner set - 3337- .
Installing
Install in reverse order of removal, observing the following:
Note
♦ Threads of new Lambda probes are already coated with as‐
sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used Lambda probe grease only the thread
with high-temperature paste - G 052 112 A3- . The high-tem‐
perature paste must not get into the slots on the probe body.
♦ When installing, the Lambda probe's electrical wiring connec‐
tion must always be re-attached in the same locations to
prevent the Lambda probe cable from coming into contact with
the exhaust pipe.
Specified torques
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 350
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322 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
8 Senders and sensors
⇒ “8.1 Removing and installing air mass meter G70 ”, page 323
⇒ “8.2 Removing and installing pressure differential sender G505
”, page 324 en AG. V
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⇒ “8.4 Checking fuel pressure regulating valve
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⇒ “8.5 Removing and installing fuel pressure sender G247 ”, page
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⇒ “8.6 Checking fuel pressure sender G 247 ”, page 332
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⇒ “8.7 Checking fuel metering valve N 290 ”, page 333
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8.1 Removing and installing air mass meter
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- G70-
Removing
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– Remove air filter housing ⇒ page 319 .
l purpos
– Unscrew bolts -arrows-.
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– Carefully pull air mass meter - G70- out of guide on air filter
m
housing.
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Install in reverse order of removal, observing the following:
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To ensure the proper function of the air mass meter - G70- it is
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t.
important to adhere to the following work sequences.
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♦ If the air filter element is very dirty or wet, particles of dirt or
water may reach the air mass meter and falsify the measured
air mass value. This would lead to loss of power, since a
smaller injection quantity is calculated.
♦ Always use Genuine part for air filter element.
♦ Always renew seal if damaged (infiltrating air).
♦ Use a silicone-free lubricant to install the air hose and seal.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic parts catalogue (ETKA) .
– Check for salt residue, dirt and leaves in air mass meter and
air hose (clean air side).
– Check intake port for dirt as far as the air filter element. If con‐
tamination is found, remove salt residues, dirt and leaves from
top and bottom part of air filter housing by rinsing out or using
a vacuum cleaner if necessary.
– Install air filter housing ⇒ page 319 .
Specified torques
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 318
8. Senders and sensors 323
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
8.2 Removing and installing pressure differ‐
ential sender - G505-
Special tools and workshop equipment required
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-
Removing AG. Volkswagen AG d
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– Before pulling off, spray hoses of pressure differential sender
d by
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- G505- with solvent. orise nte
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– Pull off electrical connector -2-. ss a c
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– Remove screw -4-.
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– Carefully pull hoses off connecting pieces in a straight line.
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The connecting pieces break off very easily.
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– Unscrew bolt -3- and remove pressure differential sender -
h re
ole,
G505- .
spec
urposes, in part or in wh
Installing
t to the co
Install in reverse order of removal, observing the following:
rrectne
Note
ss o
♦ Before installing, blow out control line of pressure differential
cial p
f in
sender - G505- leading to particulate filter with compressed air
form
mer
towards particulate filter (blocked or iced up due to conden‐
atio
sation).
om
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♦ Make sure that hoses are securely fitted and seal properly.
thi
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♦ If the pressure line on the particulate filter was loosened, tight‐
i
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en pressure line.
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– An adaptation must be performed after renewing pressure dif‐ t. C rig
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ferential sender - G505- and/or particulate filter ⇒ Vehicle p by
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diagnostic tester.
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Specified torques
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 350
8.3 Removing and installing fuel pressure
regulating valve - N276-
Special tools and workshop equipment required
324 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
♦ Open end spanner insert, AF 36 mm - V.A.G 1332/8-
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♦ Engine bung set - VAS 6122-
es, in part or in w
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8. Senders and sensors 325
Caddy 2011 ➤ agen
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Fuel pressure regulating valve au - N276- -arrow- is
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located in the or
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high pressure accumulator. sIts maintains constantpressure in the
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high pressure accumulator and injection lines (fuel high pressure
un
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circuit).
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If the pressure in the high-pressure fuel circuit is too high, the
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regulating valve opens to allow some of the fuel to flow back from
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the high-pressure accumulator to the fuel tank via a return line.
h re
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spec
If the pressure in the high-pressure fuel circuit is too low, the fuel
es, in part or in w
pressure regulating valve - N276- closes and seals off the high-
t to the co
pressure section of the system from the low-pressure section.
Removing
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WARNING
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♦ Observe rules for cleanliness and the instructions for
nform
ercia
working on the fuel system ⇒ page 8 .
m
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♦ Always follow these rules for cleanliness and instructions
com
tion in
before starting work and while working on the fuel system.
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– Removing high-pressure accumulator ⇒ page 286 .
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– Clean threaded area around fuel pressure regulating valve - t. Cop py
N276- (e.g. with commercially available cleaning solution)
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Under no circumstances may dirt enter the hole of the fuel rail.
AG.
Note
Do not allow any cleaning agent to get into the connector, clean
it carefully.
– Dry fuel pressure regulating valve - N276- .
– Loosen and unscrew fuel pressure regulating valve - N276- .
– Extract dirt from inside of fuel rail (threads and sealing sur‐
face). Do not use tools or other instruments for this purpose.
– Seal hole in fuel rail with a clean plug.
Installing
Install in reverse order of removal, observing the following:
WARNING
If the fuel pressure regulating valve - N276- has been renewed,
the learnt values for the fuel system must be reset ⇒ Vehicle
diagnostic tester.
326 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Note
♦ The fuel pressure regulating valve - N 276- cannot be re-used.
♦ Make sure that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are un‐
damaged.
♦ Check sealing surface hole.
♦ Lubricate thread and deformable sealing lip of fuel pressure
regulating valve - N276- with Molybdenum grease.
– Tighten fuel pressure regulating valve - N 276- by hand. wagen AG. Volkswagen AG doe
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– Align new fuel pressure regulating valve so that connecting
ed by ara
line is free of tension after connector is attached.
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– Tighten using torque wrench (40 … 200 Nm)
ss - V.A.G 1332-
ce
with open end spanner insert, AF 36 mm - V.A.G 1332/8- .
le
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– Install high-pressure accumulator ⇒ page 286 .
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– After mounting, leave engine running at moderate speed for a
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few minutes and then switch off again.
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– Check fuel system for leaks.
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– Read event memory.
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– Then test drive the vehicle, accelerating to full throttle at least
once.
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– Then check high-pressure section of fuel system again for
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leakage.
– Read event memory again.
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Specified torques
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
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8.4 Checking fuel pressure regulating valve
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- N276-
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Special tools and workshop equipment required t. C rig
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♦ Measuring glass - V.A.G 1602/1-
co Vo
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8. Senders and sensors 327
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Engine bung set - VAS 6122-
♦ Measuring container, fuel-resistant
WARNING
♦ Read through the rules for cleanliness and the instructions
for working on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
before starting work and while working on the fuel system.
• Engine at operating temperature.
• Air conditioner switched off
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♦ A fuel pressure regulating valve - N 276- leaking during start‐
ce
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ing will result in an increased return flow rate.
un
pt
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♦ The fuel high-pressure required for starting will not be ach‐
rm
ab
ieved.
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Sequence of operations
hole
spec
– Remove noise insulation from injectors.
es, in part or in w
t to the co
– Remove fuel return hose from high pressure accumulator, re‐
leasing hose clip -arrow- to do so.
– Seal open fuel return hose using a bung from engine bung set rrectness of i
- VAS 6122- .
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Prote AG.
328 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Connect auxiliary hose -2- to return connection of high pres‐
sure accumulator -3-.
– Hold auxiliary hose in measuring container -4- to measure re‐
turn quantity.
1) Check with engine running
– Start engine and run at idling speed for 30 seconds.
• Specified amount in 30 seconds: ≥75 ml
If the specification is not attained, the fuel pressure regulating
valve - N 276- is defective.
2) Check with engine running
If condition specified under 1) is met, increase engine speed to ≥
2000 rpm.
• Specification: return volume 0 ml
• Droplets are allowed
• If the specification is not attained, the fuel pressure regulating
valve - N 276- is defective. wage
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3) Engine cannot be started. ed by ara
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Carry out check at starter speed. utho eo
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• Specification: return volume 0 ml
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• Droplets are allowed
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• If the specification is not attained, the fuel pressure regulating
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valve - N 276- is defective.
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8.5 Removing and installing fuel pressure
es, in part or in w
t to the co
sender - G247-
Special tools and workshop equipment required
rrectness of i
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
l purpos
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♦ Engine bung set - VAS 6122- Prote AG.
8. Senders and sensors 329
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ The fuel pressure sender - G247- -2-is located in the high-
pressure accumulator. It measures the current fuel pressure
in the high-pressure system and sends a voltage signal to the
engine control unit - J623- .
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The fuel pressure sender - G247- is located in the fuel rail, meas‐
ot
ures the current fuel pressure in the high-pressure system and
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transmits a voltage signal to the diesel direct injection system
hole
control unit - J248- .
spec
es, in part or in w
t to the co
If the sender fails, the pressure is regulated by the engine control
unit using a map. In limp home mode, the maximum engine speed
is limited to approx. 3000 rpm.
rrectness of i
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Caution
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Read through the rules for cleanliness and the instructions for
m
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working on the fuel system ⇒ page 8 .
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Follow these instructions before starting work and while work‐
te o
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ing on the fuel system.
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– Clean threaded area around fuel pressure sender (e.g. with
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cold cleaning solvent) before removing. Always ensure that no ht. rig
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dirt enters the hole in the high pressure accumulator.
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Note
Do not allow any cleaning agent to get into the connector, clean
it carefully.
330 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Dry fuel pressure sender - G247- -2-.
– Pull electrical connector -1- off fuel pressure sender - G247-
-2-.
olkswagen AG
en AG. V
– Unscrew fuel pressure sender - G247- -2-.
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– Use suction device to extract dirt from
rise high-pressure accumu‐ nte
lator hole (threads and sealingausurface).
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Do not use tools or eo
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other instruments for this purpose.
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Seal the high-pressure accumulator hole immediately. The in‐
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gress of dirt must be prevented with a suitable sealing plug.
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Installing
t to the co
Install in reverse order of removal, observing the following:
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♦ Fuel pressure sender - G247- has a deformable sealing lip,
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not a seal, for sealing purposes.
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♦ Check that sealing surfaces (deformable sealing lip) and
om
threads on fuel pressure sender - G247- are undamaged. Re‐
n in
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using fuel pressure sender - G247- if possible if it has been
thi
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tested OK.
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♦ Also check sealing surface in hole of high pressure accumu‐
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ulating valve - N276- must be moistened with diesel.
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– Tighten fuel pressure sender - G247- by hand.
– Tighten fuel pressure sender - G247- to specified torque.
Note
The high-pressure connections must “not” be opened for bleed‐
ing; fuel system bleeds itself automatically.
– Filling/bleeding high-pressure pump/fuel system ⇒ page 268 .
– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
– Check fuel system for leaks.
– Read event memory again. Clear faults, if necessary.
– Switch off ignition.
– Renew the affected component if leakage still occurs after
tightening to the correct torque.
– Then test drive the vehicle, accelerating to full throttle at least
once. Check high pressure part of fuel system again for leaks.
8. Senders and sensors 331
Caddy 2011 ➤ AG. Volkswagen AG d
agen
4-cylinder diesel engine
Volksw (1.6 l engine, common
oes
rail)
not - Edition 07.2019
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If there is still air in the fuel system, the engine can change to
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emergency running mode during road test. Switch off engine and
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delete event memory. Then continue with a road test.
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– Read event memory again.
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urposes, in part or in wh
Specified torques
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♦ ⇒ “1.3 Assembly overview - fuel system”, page 265
rrectne
8.6 Checking fuel pressure sender - G 247-
ss o
WARNING
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mer
♦ Read through the rules for cleanliness and the instructions
atio
m
for working on the fuel system ⇒ page 8 .
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♦ Always follow these rules for cleanliness and instructions
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before starting work and while working on the fuel system.
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Sequence of operations Cop py
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♦ Fuel pressure sender - G 247- -2- is located in fuel rail. It
measures the current fuel pressure in the high-pressure sys‐
tem and transmits a voltage signal to the engine control unit -
J623- .
♦ If engine cannot be started though it can be with the connector
removed, fuel pressure sender - G 247- is defective.
♦ With connector removed, a substitute value is taken from con‐
trol unit for starting. If engine start is not possible with con‐
nector removed, the problem is not on fuel pressure sender -
G 247- .
♦ In the event of sender failure, pressure regulation is controlled
using a map from the engine control unit.
♦ In limp home mode, the maximum engine speed is limited to
approx. 3000 rpm.
– Disconnect electrical connector -1- at fuel pressure sender -
G 247- -2-.
– Perform check as described.
♦ Carry out electrical tests for fuel pressure sender - G 247- us‐
ing ⇒ Vehicle diagnostic tester.
332 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
8.7 Checking fuel metering valve - N 290-
Sequence of operations
– With engine running, remove connector from fuel metering
valve - N 290- -2-.
Note
Valve is closed without power.
♦ If engine stalls: fuel metering valve - N290- OK.
♦ If engine continues running: renew high-pressure pump
⇒ page 302 .
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8. Senders and sensors 333
Caddy 2011 ➤ agen
AG. Volkswagen AG d
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4-cylinder diesel engine (1.6 l engine,
by V common rail) - Edition 07.2019
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9 Engine control unit
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⇒ “9.1 Removing and installing engine (motor) control unit J623
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”, page 334
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9.1 Removing and installing engine (motor)
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control unit - J623-
Special tools and workshop equipment required
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♦ Vehicle diagnostic tester
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If the engine control unit is to be replaced, connect ⇒ Vehicle di‐
agnostic tester and carry out “Renew control unit”.
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– Switch off ignition.
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– Remove plenum chamber bulkhead ⇒ General body repairs;
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Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
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– Completely unscrew bolts -arrows- of control unit cover.
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– Undo nuts -arrows- of control unit bracket.
– Release connector from engine control unit and pull off.
– Press catches -1- and -2- outwards. Then pull engine control
unit off control unit bracket in -direction of arrow-.
Installing
Install in reverse order of removal, observing the following:
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Attach and lock connectors.
334 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Tighten nut -arrows-.
– Tighten bolts -arrows-.
– Check previous coding and adapt new control unit ⇒ Vehicle
diagnostic tester.
– Read event memory of new engine control unit and clear if
necessary ⇒ Vehicle diagnostic tester.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Carry out road test.
– Again read control unit event memory.
Specified torque
Component Specified torque
Nut 10 Nm
Bolt 5 Nm
9.2 Removing and installing anti-theft en‐
gine control unit - J623-
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♦ Vehicle diagnostic tester isedb ara
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Removing aut ra
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If the engine control unit is to be replaced, connect ⇒ Vehicle di‐
ce
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un
pt
agnostic tester and carry out “Renew control unit”.
an
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– Switch off ignition.
ility
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– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
wit
is n
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screen wiper system; Removing and installing wiper arms .
ole,
spec
urposes, in part or in wh
– Remove plenum chamber bulkhead ⇒ General body repairs;
t to the co
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Push down retaining frame in direction of -arrow- and remove
engine control unit.
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Prote AG. 9. Engine control unit
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Caddy 2011 ➤ horis
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4-cylinder diesel engine (1.6 lssengine, common rail) - Edition 07.2019
a ra
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pt
– Unscrew shear-head bolts -arrows- using a pair of pliers.
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– Insert screwdriver between both locking plates -arrow-.
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– Carefully press screwdriver in -direction of arrow- and bend
com
tio
retaining bar -1- upwards at the same time.
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– Bend retaining bar -1- in -direction of arrow- until it can be
pulled off connector.
– Push locking devices of connectors in -direction of arrow- and
pull off connectors.
Installing
Install in reverse order of removal, observing the following:
336 Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Fit connectors to engine control unit and push locking devices
to stop in -direction of arrow-.
– Fit retaining bar -1- onto connectors and press it in direction
of -arrow-.
– Guide pin -2- to stop into hole on valve timing housing.
– Use new shear-head bolts to secure retaining bar to engine
control unit -arrows-.
n AG. Volkswagen AG do
– Tighten shear-head bolts -arrows- uniformly until bolt heads ksw
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urposes, in part or in wh
– Place engine control unit into retaining frame and push up‐
t to the co
wards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
rrectne
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
s
screen wiper system; Removing and installing wiper arms .
s o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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9. Engine control unit 337
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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26 – Exhaust system byV gu
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1 Exhaust pipes and silencers
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⇒ “1.1 Assembly overview - silencers”, page 338
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⇒ “1.2 Separating exhaust pipes from silencers”, page 339
wit
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⇒ “1.3 Aligning exhaust system free of stress”, page 340
hole
spec
⇒ “1.4 Installation position of clamp”, page 341
es, in part or in w
t to the co
1.1 Assembly overview - silencers
rrectness of i
Note
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♦ After working on the exhaust system, ensure that the system
nf
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is not under stress and that there is sufficient clearance to the
o
bodywork. If necessary, loosen double clamp and align si‐
rm
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atio
lencer and exhaust pipe so that sufficient clearance is main‐
om
tained to the bodywork and the support rings are evenly
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loaded.
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♦ Renew self-locking nuts.
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1 - Clamping sleeve opy
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❑ Before tightening, align by c lksw
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cold exhaust system Prote AG.
free of tension
❑ Fitting position
⇒ page 341
❑ Tighten bolted connec‐
tions evenly.
❑ 25 Nm
2 - Front silencer
3 - Retaining ring for front si‐
lencer
❑ Renew if damaged
4 - Bracket
❑ Observe installation po‐
sition
5 - Bolt
❑ 25 Nm
6 - Mounting
❑ With retaining ring
❑ Renew if damaged
7 - Rear silencer
8 - Coupling point
❑ Marked by indentation
on exhaust pipe.
❑ During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
338 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
❑ The connection is made with a clamp.
❑ Installation position of rear clamp ⇒ page 341
❑ Evenly tighten threaded connections of clamping sleeve
❑ Cutting exhaust pipe ⇒ page 339 .
9 - Bracket
❑ Observe installation position
10 - Retaining ring for rear silencer
❑ Renew if damaged
11 - Tunnel cross-piece
1.2 Separating exhaust pipes from silencers
Special tools and workshop equipment required
♦ Chain-type pipe cutter - VAS 6254-
AG. Volkswagen AG d
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♦ or body saw - VAS 6780-
es, in part or in w
t to the co
rrectness of i
l purpos
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Prote AG.
1. Exhaust pipes and silencers 339
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
– Cut through exhaust pipe at right angles at separating point
-arrow A- using chain pipe cutter - VAS 6254- or body saw -
VAS 6780- .
– When installing, fit repair double clamp at side markings
-arrows B-.
1.3 Aligning exhaust system free of stress
Sequence of operations
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• The exhaust system must be aligned when cold. lkswage es n
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– Loosen threaded connection -3- and -4-. o
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– Align clamp -1- with marking -A- on front exhaust pipe
ss
a -2- ac
(-arrow- points in direction of travel).
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pt
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• Dimension -a- = 5 mm
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• Do not allow the bolts must be on the right and the ends to
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protrude beyond the lower edge of the clamp.
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spec
es, in part or in w
t to the co
rrectness of i
– Push rear silencer -2- forwards into clamp until dimension
-a- of 15…17 mm is attained on bracket -1- between mount‐
l purpos
ings for body and rear silencer.
nform
ercia
– Align rear silencer -2- horizontally.
m
– Tighten double clamp bolts in this position.
at
om
ion
c
– Once bolts have been tightened, check distance -a- and cor‐
in t
or
his
e
rect if necessary.
at
do
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Specified torques
um
for
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ng
t.
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♦ ⇒ “1.1 Assembly overview - silencers”, page 338
Co
Cop py
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Prote AG.
340 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1.4 Installation position of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and mounting dimensions of clamping sleeve.
Clamp -A- with 2 individual clips.
Specified torque 25 Nm
Clamp -B- with continuous clip.
Specified torque 35 Nm
Installation dimension -a- for vehicles with marking on front ex‐
haust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
a - Installation dimension -a- = 5 mm
A - Marking
Installation dimension (for front clamping sleeve only)
AG. Volkswagen AG d
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Installation position of clamp ed b y gu
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– Install clamp so that end aut of bolt -arrow- does not extend be‐
h
ra
yond lower edge of clamp.
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nl
pt
• The threaded connection of the front clamp faces to the right.
du
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• The threaded connection of the rear clamp faces to the rear.
ab
ility
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es, in part or in w
t to the co
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341
AG.
1. Exhaust pipes and silencers
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2 Emission control
⇒ “2.1 Assembly overview - catalytic converter”, page 342
⇒ “2.2 Assembly overview - particulate filter”, page 344
⇒ “2.3 Removing and installing particulate filter”, page 345
2.1 Assembly overview - catalytic converter
Note
♦ After working on the exhaust system, ensure that the system
is not under stress and that there is sufficient clearance to the
bodywork.
♦ If necessary, loosen double and single clamps and align si‐
lencers and exhaust pipe so that sufficient clearance is main‐
tained to the bodywork and the support rings are evenly loaded
⇒ page 340 .
♦ Do not bend the flexible joint in the front exhaust pipe by more
than 10° because it might otherwise be damaged.
♦ Renew seals, gaskets and self-locking nuts.
♦ EU3 vehicles have a catalytic converter instead of a particulate wage
n AG. Volkswagen AG do
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♦ The following components are not installed on EU3 vehicles.
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♦ Pressure differential sender - G505- ⇒ Item 1 (page 344)
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♦ Exhaust gas temperature sender 3 - G495-
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⇒ Item 9 (page 344)
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♦ Exhaust gas temperature sender 4 - G648-
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⇒ Item 6 (page 344)
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hole
spec
♦ Lambda probe - G39- ⇒ Item 5 (page 344)
es, in part or in w
t to the co
♦ Bracket ⇒ Item 6 (page 350)
rrectness of i
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Prote AG.
342 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
1 - Catalytic converter
2 - Seal
❑ Renew after removal agen
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❑ Observe installation po‐ d byV
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❑ 7 Nm
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5 - Nut ot p
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❑ 25 Nm
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spec
6 - Bracket
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❑ Renew
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❑ Particulate filter bracket
with riveted studs ⇒
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Electronic parts cata‐
logue .
s
❑ This is the only way to
s o
apply the necessary
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f in
specified torque.
form
mer
atio
7 - Nut
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n
c
❑ 25 Nm
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Do not bend the flexible joint in the front exhaust pipe by more
than 10° because it might otherwise be damaged.
If the catalytic converter is to be re-installed, a transportation lock
- T10403- -arrow- must always be secured to the flexible joint in
front exhaust pipe.
2. Emission control 343
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
2.2 Assembly overview - particulate filter
1 - Pressure differential sender
- G505-
❑ Removing and installing
⇒ page 324
2 - Connector
3 - Nut
❑ 10 Nm
4 - Shield
5 - Lambda probe - G39-
❑ With Lambda probe
heater - Z19- .
❑ 52 Nm
❑ Removing and installing
⇒ page 321
6 - Exhaust gas temperature
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10 - Bolt
❑ 25 Nm
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11 - Mounting
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12 - Particulate filter
❑ Removing and installing ⇒ page 345
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13 - Bolt
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❑ 25 Nm
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18 - Bolt
❑ 3 Nm
19 - Bolt
❑ 3 Nm
20 - Nut
❑ 8 Nm
344 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
21 - Clip
❑ Renew after removal
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♦ Transport lock - T10404-
Removing
– Disconnect connector -2- for exhaust gas temperature sender
1 - G235- .
– Remove exhaust gas temperature sender 3 - G495-
⇒ page 352 .
– Remove Lambda probe - G39- ⇒ page 321 .
– Remove exhaust gas temperature sender 4 - G648-
⇒ page 354 .
2. Emission control 345
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Remove clamp -1- between particulate filter and turbocharger.
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– Disconnect connector -2- on pressure differential sender -
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– Unclip lines for pressure differential sender - G505- from upper
toothed belt guard together with bracket -1-.
– Place pressure differential sender - G505- on the particulate
filter.
– Lower subframe ⇒ Running gear, axles, steering; Rep. gr.
40 ; Subframe; Lowering subframe .
346 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -1- for heat shield.
– Remove heat shield for right drive shaft.
– Remove right drive shafts ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
– Unscrew nuts -1- using ratchet wrench - T10384- .
– Unscrew nuts -2-.
– Remove particulate filter bracket.
Note
Do not bend de-coupling element in front exhaust pipe by more
than 10°.
– Loosen clamp nutssw
-arrow-.
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s c
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2. Emission control 347
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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front exhaust pipe. s
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– Remove particulate filter by turning it 180° in
-direction of arrow-.
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Note
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♦ Attach cable ties in all the same places when installing.
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Electronic parts catalogue (ETKA) .
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Observe sequence when installing particulate filter:
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1) Position particulate filter on turbo charger and loosely attach clip -1-
2) Screw bolts and nuts -2…5- in by hand
• It must still be possible to move particulate filter and bracket
3) Tighten clip -1-
4) Tighten nuts and bolts -2- and -5-
5) Tighten nuts and bolts -3- and -4-
348 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Make sure that the cables are in the correct position. They are
held in position together on the heat shield by clip -A-.
– Align exhaust system free of stress ⇒ page 340 .
– If particulate filter or pressure differential sensor - G505- has
been renewed, pressure differential sensor - G505- must be
adapted using ⇒ Vehicle diagnostic tester.
Specified torques
♦ ⇒ “2.2 Assembly overview - particulate filter”, page 344
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 350
♦ ⇒ “1.1 Assembly overview - silencers”, page 338
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2. Emission control 349
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
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4 G648 ”, page 354
3.1 Assembly overview - exhaust gas temperature regulation
rrectness of i
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Caution
Threads of exhaust gas temperature sender -G495- and -
nform
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G648- are coated. Do NOT additionally grease with high-
m
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a
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tightening torque. Otherwise, the threaded connection can be‐
n in
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come loose and subsequent failures can then occur.
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❑ Assembly overview
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⇒ page 344
❑ Removing and installing
⇒ page 345
3 - Nut
❑ 9 Nm
4 - Bracket
❑ Bolted to diesel particu‐
late filter
5 - Hose
6 - Bracket
❑ For pressure differential
sender - G505- .
7 - Pressure differential sender
- G505-
❑ Removing and installing
⇒ page 324
8 - Bracket
9 - Bolt
❑ 4.5 Nm
10 - Bolt
❑ 8 Nm
11 - Exhaust gas temperature
sender 3 - G495-
❑ Thread of sender is
coated.
❑ Do not additionally oil or
grease.
350 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
agen 4-cylinder diesel
AG. Volkswagen AG dengine (1.6 l engine, common rail) - Edition 07.2019
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❑ Removing
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❑ Grease only thread with high-temperature paste - G 052 112 A3- . High-temperature paste must not get
an
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❑ 52 Nm
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❑ Removing and installing ⇒ page 321
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13 - Exhaust gas temperature sender 4 - G648-
urposes, in part or in wh
❑ Thread of sender is coated.
t to the co
❑ Do not additionally oil or grease.
❑ 45 Nm
rrectne
❑ Removing and installing ⇒ page 354
s
14 - Exhaust gas temperature sender 1 - G235-
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cial p
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❑ 45 Nm
inform
mer
❑ Removing and installing ⇒ page 351
atio
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3.2 Removing and installing exhaust gas
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temperature sender 1 - G235-
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- p by
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♦ Tool insert, AF 17 mm - T10395-
3. Exhaust gas temperature regulation 351
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
AG. Volkswagen AG d
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– Disconnect connector -2- for exhaust gas temperature
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sender eo
1 - G235- . ss a ra
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– Remove noise insulation ⇒ General body repairs, exterior;
nl
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– Unscrew exhaust temperature sender 1 - G235- -1- and re‐
l purpos
move from exhaust manifold from below.
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Installation position of exhaust gas temperature sender -G235- .
by lksw
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• Angled shaft must have a distance -a- = 3 … 5 mm to bolting
of turbocharger support.
WARNING
The torque wrench - V.A.G 1331- must be set to 28 Nm in this
case.
Extending the torque wrench - V.A.G 1331- with the spanner
from tool set - T10395/7- allows the correct torque of 45 Nm to
be achieved.
– Then, tighten using torque wrench - V.A.G 1331- together with
wrench from tool set - T10395/7- .
Specified torques
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 350
3.3 Removing and installing exhaust gas
temperature sender 3 - G495-
Special tools and workshop equipment required
352 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332- agen
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Caution
by lksw
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Prote AG.
Thread of exhaust gas temperature sender 3 - G495- is coated.
Do NOT additionally grease with high temperature paste and
always adhere to the prescribed tightening torque
⇒ page 350 . Otherwise, the threaded connection can become
loose and subsequent failures can then occur.
Removing
– Remove Lambda probe - G39- ⇒ page 321 .
– Separate electrical connector -1- for exhaust temperature
sender 3 - G495- and move electrical wire aside.
Note
-Items 2 and 3- can be disregarded.
3. Exhaust gas temperature regulation 353
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew exhaust gas temperature sender 1 - G495- in direc‐
tion opposite to direction of -arrow-.
Installing
Install in reverse order of removal, observing the following:
– Attach cable ties in all the same places when installing.
Installation position of exhaust temperature sender 3 - G495-
-item 1-:
• Angled end facing left side of vehicle. AG. Volkswagen AG d
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The torque wrench - V.A.G 1331- must be set to 29 Nm in this
an
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Extending the torque wrench - V.A.G 1331- with the spanner
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urposes, in part or in wh
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– Lubricate thread of sender using high-temperature paste - G
052 112 A3- .
rrectne
– Screw exhaust temperature sender 1 - G495- in by hand.
s
– Then apply tightening torque using torque wrench - V.A.G
s o
1331- together with wrench from tool set - T10395/6- .
cial p
f inform
– Install Lambda probe - G39- ⇒ page 321 .
mer
atio
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Specified torques
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♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
te
sd
a
tion”, page 350
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3.4 Removing and installing exhaust gas
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Prote AG.
temperature sender 4 - G648-
Special tools and workshop equipment required
354 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench (40 to 200 Nm) - V.A.G 1332-
♦ Tool insert, AF 17 mm - T10395-
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Caution
spec
es, in part or in w
t to the co
Thread of exhaust gas temperature sender 4 - G648- is coated.
Do NOT additionally grease with high temperature paste and
always adhere to the prescribed tightening torque
rrectness of i
⇒ page 350 . Otherwise, the threaded connection can become
loose and subsequent failures can then occur.
l purpos
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– Pull out wiring connector -1- for exhaust gas temperature
om
sender 4 - G648- from bracket -2- behind battery, release and
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– Disconnect electrical connector -1- and free electrical wiring.
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3. Exhaust gas temperature regulation 355
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-
from exhaust pipe downstream of particulate filter.
Note
Disregard -item 2-. agen
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Specified torques
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♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
erm
ab
tion”, page 350
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356 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
4 Exhaust gas recirculation
⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 357
⇒ “4.2 Checking changeover for exhaust gas recirculation cooler”,
page 358
olkswagen AG
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⇒ “4.3 Removing and installing exhaust gas recirculation
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1 - Bolts
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❑ Qty. 2
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❑ 9 Nm
2 - Exhaust gas recirculation
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pipe
❑ Install so that compo‐
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cted AG.
agen
⇒ page 270
6 - Bolts
❑ Qty. 2
❑ 9 Nm
7 - Seal
❑ Renew after removal
8 - Exhaust gas recirculation
pipe
❑ Install so that compo‐
nent is not under tension
9 - Bolts
❑ Qty. 2
❑ 9 Nm
10 - Clip
❑ 4 Nm
11 - Exhaust gas recirculation cooler
❑ With integrated exhaust gas recirculation valve 1 - GX5-
❑ Checking changeover ⇒ page 358 .
❑ Removing and installing ⇒ page 359
4. Exhaust gas recirculation 357
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
12 - Bolt
❑ 9 Nm
13 - Seal
❑ Renew after removal wage
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16 - Nuts
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es, in part or in w
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17 - Bolts
❑ Qty. 2
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❑ Specified torque ⇒ Item 11 (page 188)
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❑ Renew after removal
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4.2 Checking changeover for exhaust gas
ion
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ate
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Special tools and workshop equipment required
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♦ Hand operated vacuum pump - VAS 6213-
Co
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Sequence of operations
– Pull off heat protection -2- from vacuum servo element.
358 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Pull off vacuum hose -1- from vacuum servo element and con‐
nect hand vacuum pump - VAS 6213- in its place.
– Operate hand vacuum pump to create a vacuum.
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Vol
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♦ Vacuum actuator is defective.
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♦ Changeover flap for exhaust gas recirculation is tight.
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– Fit heat shield sleeve in the same place when installing.
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4.3 Removing and installing exhaust gas re‐
spec
urposes, in part or in wh
circulation cooler
t to the co
Special tools and workshop equipment required
rrectne
♦ Hose clamps to 25 mm - 3094-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- cted agen
Prote AG.
♦ Drip tray for workshop hoist - VAS 6208-
4. Exhaust gas recirculation 359
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Spring-type clip pliers - VAS 6362-
Removing
– Remove particulate filter ⇒ page 345 .
– Press release buttons and remove hose -1- for venting crank‐
case.
– Move clear vacuum hoses -arrows-.
– Remove air pipe from air filter housing; release hose clip -3-
for this.
– Unscrew bolt -2-, swing air pipe with inlet connection to rear
and pull off from turbocharger.
– Loosen hose clip -1- and remove pulsation damper -2-.swagen AG. Volkswagen AG does
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– Unscrew bolts -arrows-. ed by ara
nte
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spec
es, in part or in w
t to the co
– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
lation.
rrectness of i
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Prote AG.
360 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line.
– Place drip tray - VAS 6208- beneath engine.
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– Clamp off coolant hoses -1- and -3- with hose clamps to 25 mm
is n
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- 3094- , loosen hose clips and remove hoses from exhaust
ole,
spec
gas recirculation cooler.
urposes, in part or in wh
t to the co
– Disconnect electrical connector -2-.
– Remove vacuum hose -4- from vacuum unit and free.
rrectne
– Unscrew bolts -arrows- and remove exhaust gas recirculation
cooler.
ss
Installing
o
cial p
f inform
Install in reverse order of removal, observing the following:
mer
atio
om
n
c
Note i
or
n thi
te
sd
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♦ Renew gaskets, seals, O-rings and self-locking nuts ⇒ Elec‐
pr
cum
r
fo
tronic parts catalogue (ETKA) .
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ng
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♦ Hose unions and air intake pipes and hoses must be free of C py
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oil and grease before installation.
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– Install exhaust gas recirculation pipes free of stress. To ach‐
AG.
ieve this, start all bolts hand-tight first, and tighten them diag‐
onally and alternately after.
– Checking engine oil level ⇒ page 173 .
– Check coolant level ⇒ page 194 .
Specified torques
♦ ⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 357
♦ ⇒ “2.2 Assembly overview - particulate filter”, page 344
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 350
4.4 Checking exhaust gas recirculation
cooler for leaks
Special tools and workshop equipment required
♦ Vehicle diagnostic tester
The exhaust gas recirculation cooler is checked for leaks with
⇒ Vehicle diagnostic tester.
– Connect ⇒ Vehicle diagnostic tester.
– Select test program and follow instructions ⇒ Vehicle diag‐
nostic tester, 01 - 4-cylinder diesel engine J623 , 19
4. Exhaust gas recirculation 361
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
- Cooling , Sub-systems, constraints , Cooling system
leaks .
4.5 Cleaning exhaust gas recirculation sys‐
tem
⇒ “4.5.1 Explanation”, page 362
⇒ “4.5.2 Initiating cleaning of exhaust gas recirculation system”,
page 362
⇒ “4.5.3 Cleaning connecting pipes and pipe union”, page 367
4.5.1 Explanation
Sequence of operations
Note
It is only possible to perform the cleaning process on exhaust gas
recirculation modules as of part number - 03L 131 512 DQ- .
. Volkswagen AG
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– Check part number -arrow- before
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With some extreme modesorof is driving (e.g. short journeys) there
e nte
eo
is a risk of varnish and coke
aut
h deposits building up on the inside of ra
the exhaust gas recirculation
ss cooler. In this case, the exhaust c
ce
emissions warning lamp lights up in the dash panel insert, and
e
nl
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the following codes are stored in the event memory: an
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♦ P0401 “EGR system flow rate too low”
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♦ P046C “Exhaust gas recirculation sender 1 implausible signal”
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In most cases, coking or carbonisation can be eliminated by per‐
spec
forming the flushing and cleaning procedure ⇒ page 362 .
es, in part or in w
t to the co
4.5.2 Initiating cleaning of exhaust gas recir‐
culation system
rrectness of i
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Special tools and workshop equipment required
♦ Cooler flushing system for exhaust gas recirculation - VAS 542
nform
ercia
005-
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at
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ion
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or
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ate
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♦ with:
♦ Canister - VAS 542 007/1-
♦ Hose set - VAS 542 007/2-
♦ Compressed air adapter - VAS 542 007/5-
♦ Valve positioner - VAS 542 007/6-
♦ Adapter - VAS 542 007/7-
362 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ alternative:
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es, in part or in w
t to the co
♦ Cooler flushing system for exhaust gas recirculation - VAS 542
007-
rrectness of i
♦ Vehicle diagnostic tester
♦ Cleaner - D 600 200 A2-
l purpos
Sequence of operations
nform
mercia
at
Note
om
ion
c
in t
or
♦ The process is carried out using the cooler flushing system for
his
ate
do
riv
exhaust gas recirculation - VAS 542 005- and the components
p
cum
indicated above.
for
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♦ Or:
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♦ If the cooler flushing system for exhaust gas recirculation - yri
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VAS 542 005- is not available, the cooler flushing system for
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exhaust gas recirculation - VAS 542 007- can also be used as
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an alternative.
• Before removing or installing components, it is essential to
check all O-rings and seals for damage.
• O-rings and seals must be moistened before installation (e.g.
with clean water).
• Never install dry O-rings or seals.
• Handle locking devices of suction and pressure connections
with care. Use suitable tools to loosen and tighten the locking
devices. Defective locking devices cannot be renewed.
• Check for leaks after each removal. Activate the pump - VAS
542 005/1- briefly to do this.
4. Exhaust gas recirculation 363
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Convert the following components as appropriate, or connect
them to pump - VAS 542 005/1- -1-:
♦ Canister - VAS 542 007/1-
♦ Hose set - VAS 542 007/2-
♦ Compressed air adapter - VAS 542 007/5-
♦ Adapter - VAS 542 007/7-
– Secure canister - VAS 542 007/1- -6- to cooler flushing system
for exhaust gas recirculation - VAS 542 005- .
– Secure hose set - VAS 542 007/2- -4-, -5- and -7- to pump -
VAS 542 005/1- -1- and in canister - VAS 542 007/1- -6-.
– Connect compressed air adapter - VAS 542 007/5- -3- to valve
-2-.
– If fitted, remove engine cover panel ⇒ page 47 .
– Loosen clamp -1-.
– Unscrew bolts -2-.
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– Detach exhaust gas y Vrecirculation pipe -3-.
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– Unscrew bolts -arrows-.
ole,
spec
urposes, in part or in wh
– Pull pipe connection -1- out of intake manifold.
t to the co
rrectness o
cial p
f inform
mer
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i
or
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te
– Fit adapter - VAS 542 007/7- -1- on opening of cylinder head.
sd
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– Fit genuine bolts -arrows- hand-tight.
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• Make sure that gasket is correctly seated on adapter - VAS Cop py
. rig
542 007/7- .
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Prote AG.
364 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– If fitted, remove noise insulation ⇒ General body repairs, ex‐ AG. Volkswagen AG d
terior; Rep. gr. 66 ; Noise insulation; Removing and installing agen oes
olksw not
noise insulation . db
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– Unscrew bolt -3-. utho or
a ac
ss
– Loosen clamp -1-.
ce
le
un
pt
an
– Unscrew nuts -4-.
d
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– Unscrew nuts -5-.
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– Remove bracket.
is n
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ole,
– Push particulate filter to one side.
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
– Unscrew bolts -1-.
atio
om
– Unscrew nuts -2-.
n
c
i
or
n thi
e
– Detach exhaust gas recirculation pipe -3-.
t
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– Disconnect electrical connector -4-.
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– Fit adapter - VAS 542 007/7- -1- on opening of exhaust gas
recirculation cooler.
– Fit genuine bolts -arrows- hand-tight.
• Make sure that gasket is correctly seated on adapter - VAS
542 007/7- .
– Connect supply hose - VAS 542 007/2-2- to adapter on ex‐
haust gas recirculation cooler.
– Connect return hose - VAS 542 007/2-3- to adapter on cylinder
head.
– Connect battery charger.
– Connect terminal clamps of valve positioner - VAS 542 007/6-
to vehicle battery.
– Connect terminal clamps of pump - VAS 542 007/3- or pump
- VAS 542 005/1- to vehicle battery.
4. Exhaust gas recirculation 365
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Prepare cooler flushing system for exhaust gas recirculation
– Fill canister - VAS 542 007/1- with 9 litres of warm tap water
(approx. 40°C-50°C). gen AG
. Volkswagen AG
d wa oes
olks not
– Pour 1 litre of cleaning solution - dDby600
V 200 A2- into the can‐ gu
ara
ister. orise nte
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– Connect suction hose - VAS
ss 542 007/2-1- to connection -1- on
a c
canister - VAS 542 007/1- .
ce
le
un
pt
an
d
– Insert open end of return hose - VAS 542 007/2-3- into opening
itte
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-arrow- up to approx. half canister height.
ab
pe
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– Fit electrical connector of valve positioner - VAS 542 007/6- to
wit
, is n
exhaust gas recirculation valve - N18- .
h re
hole
spec
– Switch on valve positioner - VAS 542 007/6- .
es, in part or in w
t to the co
Note
rrectness of i
♦ Ensure that the tap of the relief valve on the supply hose - VAS
l purpos
542 007/2-2- is closed.
♦ If activation of the exhaust gas recirculation valve - N18- via
nform
ercia
the valve positioner - VAS 542 007/6- including approx. 1.6 bar
pressure from the pump is not sufficient to open the exhaust
m
a
com
t
gas recirculation valve - N18- , the pump switches off after a
ion in
brief period. In this case, the exhaust gas recirculation valve -
r
te o
thi
N18- has a mechanical fault, and the exhaust gas recirculation
s
iva
do
module must be renewed. Before disconnecting the supply
r
rp
cum
hose - VAS 542 007/2-2- , carefully open the relief valve tap
fo
en
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to release the pressure, and collect the escaping cleaning sol‐
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– While the cleaning process is running, clean the connecting
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pipes ⇒ page 367 .
Prote AG.
– Actuate pump as follows:
Pump Time Scenario
Switch on 25 min. Clean
Switch off 10 min. Period for cleaning
solution to take ef‐
fect
Switch on 25 min. Clean
Switch off --- End of cleaning
process
– Detach supply hose - VAS 542 007/2-2- from canister - VAS
542 007/1- .
– Operate pump until no more cleaning solution is delivered
(system is emptied in doing so).
– Pull return hose - VAS 542 007/2-3- out of canister paying at‐
tention to escaping cleaning solution.
– Drain canister - VAS 542 007/1- .
• Observe country-specific disposal regulations.
– Fill canister - VAS 542 007/1- with 10 litres of warm tap water
(approx. 40°C-50°C).
– Connect suction hose - VAS 542 007/2-1- of pump to connec‐
tion on canister - VAS 542 007/1- .
– Feed return hose - VAS 542 007/2-3- into a suitable container
(with a capacity of at least 12 litres) and secure in place.
366 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Operate pump until entire content of canister - VAS 542 007/1-
has run through exhaust gas recirculation system.
– Release and pull off supply hose - VAS 542 007/2-2- from
adapter on exhaust gas recirculation cooler.
– Connect compressed air adapter - VAS 542 007/5- to adapter
on exhaust gas recirculation cooler.
– Insert open end of return hose - VAS 542 007/2-3- into opening
-arrow- up to approx. half canister height.
– Suction hose - VAS 542 007/2-1- of pump must be connected
to connection -1-.
– Fit compressed air line to compressed air adapter - VAS 542
007/5- , and completely blow out remaining water from ex‐
haust gas recirculation system.
• The water must be removed from the exhaust gas recirculation
system without trace. Risk of engine damage.
– Release and pull off compressed air adapter - VAS 542
007/5- .
– Detach adapter from exhaust gas recirculation cooler.
– Install pipe for exhaust gas recirculation at rear with new seals
and new nuts.
– Disconnect electrical connector of valve positioner - VAS 542
007/6- , and reconnect electrical connectors of exhaust gas
recirculation valve - N18- .
– Bring particulate filter to installation position with new gasket
and new clamp, and secure it ⇒ page 345 .
– If present, install noise insulation ⇒ General body repairs, ex‐wagen AG. Volkswagen AG does
terior; Rep. gr. 66 ; Noise insulation; Removing and installing ks not
Vol gu
by
noise insulation . ris
ed ara
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tho or
– Release and pull off return hose - VAS 542 007/2-3-
au on cylin‐ ac
ss
der head adapter.
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nl
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– Insert pipe connection back into intake manifold.
an
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– Tighten bolts; specified torques ⇒ page 188 .
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– Detach adapter on cylinder head.
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hole
– Install exhaust gas recirculation pipe at front with new seals.
spec
es, in part or in w
– Install engine cover panel if removed beforehand ⇒ page 47 . t to the co
– Therefore, read event memory and erase entries if necessary.
rrectness of i
– Carry out road test.
l purpos
– All components used for cleaning must be rinsed with clean
water after cleaning is complete.
nf
ercia
4.5.3 Cleaning connecting pipes and pipe un‐
rm
m
atio
m
ion
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or c
thi
e
Special tools and workshop equipment required
t
sd
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o
r
rp
cu
♦ Ultrasonic cleaning device - VAS 6418-
o
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Prote AG.
4. Exhaust gas recirculation 367
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Sequence of operations
AG. Volkswagen AG d
– Close drain tap -arrow-. lksw
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Note auth
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The process can be accelerated by using warm tap water. nl
pt
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itte
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ab
– Fill ultrasonic cleaning unit - VAS 6418- with 1800 ml of tap
ility
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water and 200 ml of cleaner - D 600 200 A2- .
wit
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– Insert exhaust gas recirculation pipes and pipe connections,
hole
spec
and adjust positions of components located in water if re‐
es, in part or in w
quired.
t to the co
– Switch on cleaning unit using on/off button -C-.
rrectness of i
– Turn rotary temperature switch -B- until lamp indicator is at 40°
C warm-up temperature.
l purpos
– Turn rotary switch for operating time -A- until 10 -arrows- is
indicated on scale.
nf
ercia
orm
– Press and hold ► -D- for approx. 2 seconds and bring unit into
m
atio
m
operation.
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Note
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ng
t.
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♦ Temperature-controlled cleaning is now activated.
Co
Cop py
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♦ During the warm-up period, ultrasonic waves are activated to
ht
pyri by
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mix the cleaning fluid.
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Prote AG.
♦ Once the preselected temperature is reached, the ultrasonic
waves are switched to continuous operation.
♦ Cleaning time must be at least 10 minutes, and cleaning only
starts at a temperature of at least 40°C.
– Once cleaning is complete, rinse all components with clean
water, and blow them out with compressed air.
368 Rep. gr.26 - Exhaust system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
28 – Glow plug system
1 Glow plug system
⇒ “1.1 Removing and installing glow plug”, page 369
⇒ “1.2 Checking glow plugs”, page 371
⇒ “1.3 Removing and installing automatic glow period control unit
J179 ”, page 371
⇒ “1.4 Removing and installing engine speed sender G28 ”, page
371
⇒ “1.5 Removing and installing Hall sender G40 ”, page 372
1.1 Removing and installing glow plug
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-
AG. Volkswagen AG d
agen oes
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♦ 10 mm jointed spanner - 3220-
rised ara
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ab
ility
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spec
es, in part or in w
t to the co
rrectness of i
♦ Pliers - 3314-
l purpos
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orm
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om
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Prote AG.
1. Glow plug system 369
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
Removing
– Switch off ignition.
– Remove noise insulation at injectors.
– Clean glow pin plug opening in cylinder head. It must be en‐
sured that no dirt falls into the cylinder when this is being done.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
opening, let it work in briefly and blow out with compressed air.
♦ Then use an oil-soaked cloth to clean the glow pin plug
swa
gopen‐
en AG. V
olkswagen AG
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ing. yV
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– Pull connector -B- off pressure differential
aut sender - G505- and ra
fuel pressure sender - G247- -C-. ss c
ce
e
nl
pt
– Undo bolts -arrows- of coolant line at intake manifold and put
du
an
itte
line down in front of intake manifold.
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Open cable guide catches to lay wiring harness to side.
nf
ercia
Caution
orm
m
atio
m
Make sure that no wiring connections are damaged when dis‐
o
n in
c
connecting the heater-element connectors.
or
thi
te
sd
a
Otherwise the whole wiring harness will need to be renewed.
iv
o
r
rp
cu
o
Do not close the pliers - 3314- too firmly when pulling the glow
f
en
ng
t.
plug connectors off as otherwise the support sleeve can be
yi Co
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damaged.
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Prote AG.
– Position pliers - 3314- with groove -arrow A- on support sleeve
shoulder -arrow B- and pull connectors off glow plugs.
370 Rep. gr.28 - Glow plug system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
– Carefully pull connector off glow plug in -direction of arrow-.
AG. Volkswagen AG d
agen oes
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h
aut ra
ss c
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nl
– Unscrew nut of fuel return line at intake manifold. Open clip
pt
du
an
itte
-arrow- and pull line off fuel rail.
y li
erm
ab
– Remove complete return line and put it down in front of intake
ility
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manifold.
wit
, is n
h re
hole
– To loosen glow plugs, use special tool U/J extension and
spec
10 mm socket - 3220- .
es, in part or in w
t to the co
Installing
Install in reverse order of removal, observing the following:
rrectness of i
Specified torques
l purpos
Component Specified torque
nf
ercia
Glow plug 18 Nm
orm
m
atio
m
1.2 Checking glow plugs
o
n in
or c
thi
te
sd
Check
iva
o
r
rp
The glow plug system is monitored by the engine control unit's cu
o
m
f
en
ng
self-diagnosis system.
t.
yi Co
Cop py
t. rig
Necessary checks are performed using ⇒ Vehicle diagnostic test‐ yri
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ht
er.
op Vo
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cted agen
Prote AG.
1.3 Removing and installing automatic glow
period control unit - J179-
Removing
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery tray .
– Pull out relay carrier -2- in -direction of arrow- from underneath
electronics box in engine compartment.
– Disconnect electrical connector -3-.
– Unscrew bolt -4-.
– Remove automatic glow period control unit - J179- -1-.
Installing
Install in reverse order of removal.
1.4 Removing and installing engine speed
sender - G28-
Special tools and workshop equipment required
1. Glow plug system 371
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench - V.A.G 1331-
♦ Hexagon key extension, 4 mm - T10370-
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– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
– Detach electrical connector -1- from engine speed sender - rrectness of i
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– Unscrew securing bolt -arrow- using socket 4 mm - T10370-
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Specified torques
♦ ⇒ “2.1 Assembly overview - flywheel”, page 66
1.5 Removing and installing Hall sender -
G40-
Special tools and workshop equipment required
372 Rep. gr.28 - Glow plug system
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
♦ Torque wrench - V.A.G 1331-
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– Unscrew bolt -1-.
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– Unscrew bolt -2-.
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– Unscrew nut -3-.
– Remove hose retainer -4- from fuel filter.
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– Place fuel filter -7- aside (fuel hoses -5 and 6- remain connec‐
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– Remove vibration damper ⇒ page 64 .
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– Remove toothed belt from idler pulley and high-pressure pump
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– Disconnect electrical connector -1-.
– Detach connector from retainer.
Note
Disregard items -2 and 3-.
– Remove idler roller -1-.
– Using a screwdriver, remove webs -arrows- and move wiring
harness aside.
– Remove cover -2- of repair aperture.
1. Glow plug system 373
Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 07.2019
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Install in reverse order of removal, observing the following:
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♦ Seal repair aperture in toothed belt guard with rubber plugs as itte
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– Fit toothed belt and adjust the valve timing ⇒ page 127 .
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 87
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374 Rep. gr.28 - Glow plug system
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