D3E803ECA8A-4-Cylinder Injection Engine (1 6 L Engine BiFuel)

Service
Workshop Manual
Caddy 2011 ➤
4-cylinder injection engine (1.6 l engine, BiFuel)
Engine ID
CHG
A
Edition 12.2015
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
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00 - Technical data ss a ra
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15 - Cylinder head, valve gear
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17 - Lubrication
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19 - Cooling
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20 - Fuel supply system
24 - Mixture preparation - injection
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26 - Exhaust system
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28 - Ignition 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 © 2016 Volkswagen AG, Wolfsburg D3E803ECA8A

Caddy 2011 ➤
4-cylinder injection engine (1.6 l engine, BiFuel) - Edition 12.2015
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number, engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Safety precautions when working on cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Safety precautions when working on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Safety precautions during road tests in which testing and measuring equipment is used . . 3
2.4 Safety precautions when working on Autogas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.5 Safety precautions when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.6 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 General notes on ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 Rules for cleanliness when working on fuel supply system/injection system . . . . . . . . . . . . 7
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Securing engine on engine and gearbox support VAS 6095 . . . . . . . . . . . . . . . . . . . . . . 12
1.3 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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13 - Crankshaft group wa . . . . . . . . . . . . . o.es. n. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1 Cylinder
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1.1 Assembly
aut overview - poly V-belt drive . . . . . . .or.ac. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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1.2 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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1.4 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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1.5 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.2 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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3.2 Identification of crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.3 Removing and installing sender wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
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3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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4.2 Bearing shells - installation position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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4.4 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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4.5 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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1.2 Checking cylinder head for distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.4 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.2 Removing and installing toothed belt guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3 Removing and installing toothed belt . . . . . . . . . . . . . . . . . .A.G.. .V.ol.ks.w. a.g.en. A. . . . . . . . . . . . . . 50
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2.4 Checking semi-automatic toothed belt tensioner . .Vo. lk. s.w.a . . . . . . . . . . . . . . .d.oe. s.n.ot. . . . . . . 55
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3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . r.is.ed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.n.te. . 56
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3.1 Assembly overview - valve gear . . . . . . . a.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a
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3.2 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Removing and installing camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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3.4 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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3.5 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
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3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.3 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.1 Assembly overview - sump and oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
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1.4 Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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2.1 Assembly overview - oil filter/oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
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2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
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2.3 Measure oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
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19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
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1 Cooling system, coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Draining and filling coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
1.3 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.2 Removing and installing the coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.3 Removing and installing the thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.1 Assembly overview - radiator and radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3 Removing and installing radiator fan V7 and radiator fan 2 V177 . . . . . . . . . . . . . . . . . . . . 96
20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

1 Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.1 Assembly overview - fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.2 Removing and installing fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
2 Fuel delivery unit, fuel gauge sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.1 Removing and installing the fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.2 Installation position of fuel delivery unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.3 Removing and installing the fuel gauge sender G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3 Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.1 Assembly overview - fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2 Removing and installing the fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
4 Autogas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
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4.1 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.2 Emptying the gas line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.3 Renewing filter on the Autogas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.4 Removing and installing the fuel tank (Autogas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.5 Components on fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.6 Removing and installing gas injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.7 Removing and installing pressure and temperature sensor for gas rail GX21 . . . . . . . . . . 123
4.8 Checking SERTO adapter leads for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
5 Accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.2 Assembly overview - accelerator mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
5.3 Removing and installing the accelerator module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6 Activated charcoal filter system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.2 Checking fuel tank breather . . . . . . . . . . . . . . e.n.A.G.. V. o. lk. s.w.a.ge.n.A.G. . . . . . . . . . . . . . . . . . . . . 130
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7.1 Checking fuel pump . . . . . . . . . .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . 132
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1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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1.2 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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2 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
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2.1 Assembly overview - fuel rail with injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
hole
spec
2.2 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
es, in part or in w
t to the co
2.3 Checking injectors for leaks and quantity injected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
3 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
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3.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.2 Removing and installing lower part of intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
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3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

3.4 Checking intake manifold change-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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4 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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4.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
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5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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5.1 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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6.1 Removing and installing engine control unit J623 and gas mode control unit J659 . . . . . . 163
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6.2 Removing and installing anti-theft engine control unit J623 and gas mode control unit J659 t. C rig
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...................................................................... 164
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Prote AG.
1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.2 Separating exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1.3 Installation position of clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
1.4 Checking exhaust system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
2 Emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.1 Assembly overview - emission control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
2.2 Removing and installing catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4 Secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.1 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
4.2 Assembly overview - secondary air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Contents iii
Caddy 2011 ➤
4.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.1 Removing and installing exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.1 Assembly overview - ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
1.2 Test data, spark plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
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Caddy 2011 ➤
00 – Technical data
1 Identification
(VRL008712; Edition 12.2015)
⇒ “1.1 Engine number, engine data”, page 1
1.1 Engine number, engine data

The engine number (“code letters” and “serial number”) can be
found on the left on the joint between the engine and the gearbox.
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same code
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There is also a sticker on the toothed-belt guard with the “engine
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code” and “serial number”.
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The engine code is also included on the vehicle data sticker.
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Code CHGA
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Emissions fulfil EU5 standard
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Capacity l 1.6
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Output with LPG kW at rpm 72/5600

Torque with LPG Nm at rpm 144/3800
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Output with petrol kW at rpm 75/5600

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Torque with petrol Nm at rpm 148/3800

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Bore Diameter, mm 81.0

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Compression ratio 10.3

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Injection Autogas (LPG) SIMOS 7.D
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Ignition system SIMOS 7.8

Knock control 1 sensor
Self-diagnosis yes
Lambda control 2 probes
Catalytic converter yes
Exhaust gas recirculation no
Variable intake manifold yes
Secondary air system yes
Electronic power control yes
1) Also 91 RON with reduced power.
1. Identification 1
Caddy 2011 ➤
2 Safety instructionsn AG. Volkswagen AG

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⇒ “2.1 Safety precautions wheny V working on cooling system”, page
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⇒ “2.3 Safety precautions during road tests in which testing and
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⇒ “2.5 Safety precautions when working on fuel supply system”,
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page 4
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⇒ “2.6 Safety precautions when working on injection system”,
page 5
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2.1 Safety precautions when working on
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cooling system
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Steam may escape when expansion tank is opened. Wear eye

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When doing any repair work, especially in the engine compart‐
Prote AG.
ment, pay attention to the following due to the cramped condi‐

tions:
♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
vated charcoal filter system, coolant and refrigerant, brake
fluid and vacuum) and electrical wiring in their original po‐
sitions.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
2 Rep. gr.00 - Technical data

Caddy 2011 ➤
Note
♦ When the engine is warm, the cooling system is under pres‐

sure. If necessary, release pressure before beginning repair
work.
♦ Hoses are secured with spring-type clips. In case of repair,
only use spring-type clips.
♦ When installing or removing spring-type clips, we recommend
using spring-type clip pliers - VAS 6340- or
♦ … we recommend hose clip pliers - VAS 6362- .
♦ When installing coolant hoses, route stress-free so that they
do not come into contact with other components (observe
markings on coolant connection and hose).
♦ Arrows on the coolant pipes and on the ends of the hoses must
be aligned with each other.
♦ Only demineralised
agen/ distilled waterAG
AG. Volkswagen tod standard VDE-0510
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may be used yV
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2.2 Safety precautions when working on ig‐
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To prevent injuries to persons and/or damage to the injection and

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ignition system, the following must be observed:

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♦ Do not touch or disconnect ignition cables when the engine is

spec
running or being turned at starter speed.

es, in part or in w
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♦ Switch off ignition before connecting or disconnecting injection

and ignition system wiring as well as test instrument cables.
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♦ If the engine is to be turned at starter speed without starting:

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– Pull fuses for the injectors and the ignition transformer from
the fuse holder. Fuse assignment ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
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Note the following if testers and measuring instruments have to

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be used during a road test:

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♦ Test and measuring instruments must always be secured to

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rear seat and operated by a second person from this location.

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senger seat and the vehicle is involved in an accident, there is a

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possibility that the person sitting in this seat may receive serious
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injuries when the airbag is triggered.
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– When work is completed, clear event memory of engine con‐
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trol unit since faults will have been registered as a result of
removing fuse ⇒ Vehicle diagnostic tester.
2.3 Safety precautions during road tests in

which testing and measuring equipment
is used
the rear seat and operated by a second person from this lo‐
cation.
2. Safety instructions 3
Caddy 2011 ➤
♦ Operating from the front passenger seat may result in an ac‐

cident caused by releasing the front passenger air bag which
can cause injuries to the person sitting there.
2.4 Safety precautions when working on Au‐

togas system
Caution

tions:
♦ Route all the different lines (e.g. for fuel, hydraulics, acti‐
fluid and vacuum) and electrical wiring in their original lay‐
out.
♦ To avoid damage to lines/wiring, ensure sufficient clear‐
ance to all moving or hot components.
When removing and installing the fuel gauge sender or pressure

relief valve, the inlet valve or the gas tank valve from a full or partly
full fuel tank, observe the following: AG. Volkswagen A gen G do
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♦ If the customer is given a service appointment y V and it is known
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that a tank valve will have to be replaced, ed bthe customer should ran
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or
drive the vehicle until the gas tank isuthempty before bringing the or
vehicle in for service. ss
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
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2.5 Safety precautions when working on
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fuel supply system

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♦ Fuel hoses on the engine must only be secured with spring- pyri by
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type clips which conform to the production standard.
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♦ Spring-type clip pliers - VAS 5024 A- or hose clip pliers - V.A.G
1921- are recommended for installing spring-type clips.
When removing and installing fuel gauge sender - G- or fuel pump

(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
♦ Even before work starts, the extraction hose of a fume extrac‐
tion system which is switched on must be placed in the vicinity
of the assembly opening of the fuel tank to extract any escap‐
ing fumes. If no exhaust gas extraction system is available, a

Caddy 2011 ➤
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!
2.6 Safety precautions when working on in‐

jection system
WARNING
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Fuel supply line is pressurised. Wear eye protectionbyand Vo pro‐
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tective clothing to avoid possible injury and skin contact.
ir se
d Before ran
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loosening hose connections, wrap a cloth around utho the joint. or
Then release the pressure by carefully pulling ss the hose off the
a ac
connection.
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To prevent injury to persons and/or damage to the injection and
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ignition system, the following must be observed:
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♦ Do not touch or disconnect ignition cables when the engine is
ole,
spec
running or being turned at starter speed.
urposes, in part or in wh
t to the co
♦ Switch off ignition before connecting or disconnecting injection
and ignition system wiring as well as test instrument cables.
♦ For safety reasons, when the battery is not disconnected, the
rrectne
fuse for the fuel pump must be removed from the fuse holder
before opening the fuel system, otherwise the fuel pump could
ss
be activated by the driver door contact switch. Fuse assign‐
o
cial p
f
ment ⇒ Current flow diagrams, Electrical fault finding and
inform
Fitting locations
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fluid and vacuum) and electrical wiring in their original lay‐ Prote
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agen
out.

the rear seat and operated by a second person from this lo‐
cation.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
– When work is completed, clear event memory of engine con‐
trol unit since faults will have been registered as a result of
removing fuse ⇒ Vehicle diagnostic tester.
2. Safety instructions 5
Caddy 2011 ➤
3 Repair instructions
⇒ “3.1 General notes on ignition system”, page 6
⇒ “3.2 General notes on injection”, page 6
⇒ “3.3 Foreign objects in engine”, page 7
⇒ “3.4 Rules for cleanliness when working on fuel supply system/
injection system”, page 7
3.1 General notes on ignition system

♦ For trouble-free operation of electrical components, a voltage
of at least 11.5 V is necessary.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all the checks and
repairs, read the event memory and clear it if necessary ⇒ Ve‐
hicle diagnostic tester.
♦ If the engine starts, runs for a short period and then stops after
fault finding, repairs or component tests, then the fault may be
that the immobiliser is blocking the engine control unit. In this
case, the control unit must be adapted ⇒ Vehicle diagnostic
tester.
Safety precautions ⇒ page 3 .
Test data, spark plugs ⇒ page 181
3.2 General notesswon

ageninjection AG does
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♦ If fuel system has been d b opened, it must be bled before engine
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♦ Fuel hoses in sthe
s
engine compartment must only be secured
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♦ The battery must only be disconnected with the ignition switch‐

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♦ For trouble-free operation of electrical components, a voltage

es, in part or in w
of at least 11.5 V is necessary.

t to the co
♦ Do not use sealants which contain silicone. Particles of sili‐

cone drawn into the engine will not be burnt in the engine and
rrectness of i
will damage the Lambda probe.

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♦ If the engine starts, runs for a short period and then stops after
fault finding, repairs or component tests, then the fault may be
that the immobiliser is blocking the engine control unit. In this
nform
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case, the control unit must be adjusted ⇒ Vehicle diagnostic

tester.
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♦ Certain tests may lead to a fault being detected by the control

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unit and stored. Therefore, after completing all the checks and
his
ate
repairs, read the event memory and clear it if necessary ⇒ Ve‐

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♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
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♦ When the driver door is opened, the fuel pump is activated for
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2 seconds to build up pressure in the fuel system. This im‐
proves the quality of the starting behaviour.

Caddy 2011 ➤
olkswagen AG
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3.3 Foreign objects in engine
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If large quantities of swarf or metal particles (caused, for example,
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in the engine oil when performing repairs, clean the oil passages
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thoroughly and renew the engine oil cooler in order to prevent
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3.4 Rules for cleanliness when working on
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fuel supply system/injection system
When working on the fuel supply and injection system, pay careful
rrectness of i
attention to the following “5 rules” of cleanliness:
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♦ Thoroughly clean all connections and surrounding areas be‐

fore disconnecting.
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♦ Place removed parts on a clean surface and cover. Use only
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♦ Carefully cover opened components or seal if repairs cannot

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be carried out immediately.

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♦ 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 which have not been stored in their packing (e.g. in . Cop py
tool boxes etc.).
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♦ When system is open: do not work with compressed air if this
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AG.
essary.
3. Repair instructions 7
Caddy 2011 ➤
10 – Removing and installing engine

AG. Volkswagen AG d
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1 Removing and installing engine
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⇒ “1.1 Removing engine”, page 8 aut ra
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⇒ “1.2 Securing engine on engine and gearbox support VAS 6095
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⇒ “1.3 Installing engine”, page 14
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Special tools and workshop
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equipment required
♦ Torque wrench - V.A.G
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1331-
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1332-
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♦ Engine and gearbox jack -
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V.A.G 1383 A-
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♦ Stepladder - VAS 5085-

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8 Rep. gr.10 - Removing and installing engine

Caddy 2011 ➤
Note
♦ Before carrying out further work, disconnect the battery earth

strap. Check whether a coded radio is fitted. Obtain anti-theft
coding first if necessary.
♦ The engine is removed downwards together with the gearbox.
♦ All cable ties which are opened or cut through when the engine
is removed must be reinstated in the same position when the
engine is installed.
AG. Volkswagen AG d
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When doing any repair work, especially in the engines acompart‐
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nl
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♦ Route all the various lines (e.g. for fuel, hydraulics, acti‐
erm
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ility
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fluid and vacuum) and electrical wiring in their original po‐
wit
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sitions.
h re
hole
spec
es, in part or in w
t to the co
Procedure
rrectness of i
– With ignition switched off, disconnect earth strap from battery.
l purpos
– Unscrew bolt -3- and remove the air-filter housing with the
connecting hoses.
nform
ercia
– Remove battery and battery tray ⇒ Battery; Rep. gr. 27 ; Dis‐

m
at
om
connecting and connecting battery .
ion
c
in t
or
– Remove plenum chamber bulkhead ⇒ General body repairs,
his
ate
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
do
priv
cum
or
– Pull the engine wiring harness connector off at the control unit.
f
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
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cted agen
Prote AG.
– Release feed-through for engine wiring harness -arrow- if nec‐

essary and pull off upwards.
1. Removing and installing engine 9

Caddy 2011 ➤
– Open cable duct latches on longitudinal member -arrows-.

– Disconnect the engine wiring harness/body connectors and
lay the engine wiring harness on the engine.
WARNING
AG. Volkswagen AG d
Fuel supply line is pressurised. Wear eye protection olks
and
wage pro‐
n oes
not
tective clothing to avoid possible injury and skin dcontact.
by
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loosening hose connections, wrap a clothoriaround se the joint. nte
Then release the pressure by carefully pulling the hose off the
th eo
au ra
connection. ss c
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pt
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ab
– Disconnect breather line -1- and fuel feed line -2-. To do this,
pe
ility
press the release buttons.
ot
wit
, is n
h re
hole
spec
WARNING
es, in part or in w
t to the co
Gas can escape when loosening the gas rail. Wear eye pro‐
tection and protective clothing to avoid eye injuries and burns.
Cover separating points with a cloth and open carefully.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Loosen clip -1- and pull hose off the gas rail
-in the direction of the arrow-.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 50 ; Body - front; Noise insulation .
– Bring lock carrier into service position ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body - front; Lock carrier .
– Drain coolant ⇒ page 81 . . Volkswagen AG
gen AG does
swa
– Pull off or disconnect all other electricaly Vconnections from the
olk not
gu
engine and gearbox as necessary rand ised lay open.
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– Disconnect all connection, coolant,
s au vacuum and intake hoses ra
c
from engine. s
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nl
pt
du
Vehicles with air conditioning system:
an
itte
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erm
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ility
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Caution
wit
, is n
h re
hole
To prevent damage to condenser or to refrigerant lines/hoses,
spec
ensure that the lines and hoses are not stretched, kinked or
es, in part or in w
bent.
t to the co
rrectness of i
To facilitate removing and installing engine without opening re‐
frigerant circuit:
l purpos
– Remove poly V-belt ⇒ page 20 .
nf
ercia
– Remove air conditioner compressor from bracket for ancilla‐
or
ries ⇒ page 17 .
m
m
atio
m
– Secure air conditioner compressor on the lock carrier so that

o
n in
or c
refrigerant lines are free of stress.
thi
te
sd
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Continuation for all vehicles
o
r
rp
cu
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f
en
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ;
ng
t.
yi Co
Selector mechanism . ht. Cop py
rig
rig ht
py by
Vo
– Unclip line -B- from slave cylinder of hydraulic clutch at con‐
co lksw
by
cted agen
nection (pull clip -A-). Prote AG.
– Pull out line-B- from the retainer-C-.
Note
Do not press clutch pedal after removing slave cylinder.
– Remove front exhaust pipe with catalytic converter

⇒ page 171 .
– Remove pendulum support.
– Remove right drive shaft and disconnect left drive shaft at
gearbox ⇒ Rep. gr. 40 .

Caddy 2011 ➤
– Remove grubscrew -arrows- at the front on the cylinder block.

– Insert engine bracket - T10012- in engine and gearbox jack -
V.A.G 1383 A- .
AG. Volkswagen AG d
agen oes
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– Fit engine bracket - T10012- as
ss shown in illustration, and se‐ c
cure it to cylinder block using M10 x 25/ 8.8 nut (tightening
ce
le
un
pt
torque: approx. 20 Nm).
an
d
itte
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ab
Specified torque
pe
ility
ot
wit
Component Specified torque
, is n
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hole
Engine bracket - T10012- 20 Nm
spec
es, in part or in w
t to the co
– Lift engine and gearbox slightly using engine and gearbox jack
- V.A.G 1383 A- .
rrectness of i
l purpos
– Unbolt engine side of assembly mounting from engine bracket

from above -arrows-.
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
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unbolt gearbox side of assembly mounting from gearbox

bracket -arrows- from above.
Note
♦ To remove securing bolts, use stepladder - VAS 5085- .

♦ Engines with gearbox must be guided carefully when lowered
to prevent damage to bodywork.
– Carefully lower engine with gearbox.
1.2 Securing engine on engine and gearbox support - VAS 6095-

Caddy 2011 ➤

equipment required
♦ Lifting tackle - 2024 A-
♦ Workshop hoist - VAS
6100-
♦ Engine and gearbox sup‐
port - VAS 6095-
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an
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Secure the engine to engine and gearbox support - VAS 6095- in

itte
y li
order to carry out the repairs.

rm
ab
pe
ility
ot
– Unbolt gearbox.
wit
, is n
h re
– Attach lifting tackle - 2024 A- as follows and lift from engine

hole
spec
and gearbox jack - VAS 6100- using workshop crane - V.A.G

es, in part or in w
1383 A- .
t to the co
Poly V-belt pulley end: 3rd hole in hook rail at Position 2

rrectness of i
Flywheel end: 3rd hole in hook rail at Position 8

l purpos
Caution
nform
ercia
Use securing pins on the hooks and locking pins to avoid dam‐
aging the engine and vehicle.
m
a
com
tion in
r
te o
thi
♦ The positions marked 1…4 on the bar must face towards the
s
iva
do
poly V-belt pulley end.

r
rp
cum
fo
en
g
♦ The holes in the hook rails are counted up from the hook.
n
t.
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Cop py
– Dowel sleeves must be removed.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
1.3 Installing engine

Installation is carried out in the reverse order; note the following:
Caution

tions:
out.
– Insert new dowel sleeves in the cylinder block for centring the
engine and gearbox.
– Hook intermediate plate onto sealing flange and slide onto
dowel sleeves -arrows-.
olkswagen AG
en AG. V
– Lightly grease inputoshaft
ksw splines with grease ⇒
ag does
nElectronic
V l ot g
Parts Catalogueed b(ETKA) .
y ua
ra
is nte
or
– Check clutch
au and clutch operating mechanism and install ⇒
th eo
ra
Rep. gr. ss30 . c
ce
e
nl
pt
– When installing the engine and gearbox assembly, make sure

du
an
itte
there is sufficient clearance to the subframe and radiator.

y li
erm
ab
ility
– Align engine the mountings stress-free by rocking, if neces‐

ot p
sary loosen the engine mountings on the body.

wit
, is n
h re
hole
– Install pendulum support.

spec
es, in part or in w
– Install right drive shaft and connect left drive shaft to gearbox
t to the co
⇒ Rep. gr. 40 .
– Install front exhaust pipe ⇒ page 171 .
rrectness of i
– Install selector mechanism and adjust if necessary ⇒ Rep. gr.

l purpos
34 .
nform
mercia
at
om
ion
c
in t
or
his
ate
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.

Caddy 2011 ➤
– Connect line -B- with plug-in connection to the slave cylinder

of the hydraulic clutch by engaging retaining clip -A- securely.
– Bleed clutch mechanism ⇒ Rep. gr. 30 ; Clutch mechanism .
– Install air conditioner compressor ⇒ Rep. gr. 87 ; Air condi‐
tioner compressor .
– Install poly V-belt ⇒ page 20 .
– Fit noise insulation ⇒ Rep. gr. 50 .
– Fit plenum chamber bulkhead ⇒ Rep. gr. 50 .
– Connect the gas hose to the gas rail with a new clamp.
– Replenish coolant ⇒ page 81 .
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Connect ⇒ Vehicle diagnostic tester.
– Read all the event memories and delete all the entries which
may have been entered due to assembly.
– Perform road test.
– Then carry out vehicle system test and rectify any faults which
have occurred.
Specified torques
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 16
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 17
♦ ⇒ “2.1 Assembly overview - emission control”, page 170
♦ Drive shafts; Assembly overview - drive shafts ⇒ Rep. gr. 40 ;
Assembly overview - drive shafts
olkswagen AG
en AG. V
♦ Lock carrier; Assembly overview - lock carrier
olks ⇒ Lock carrier;
wag does
not
Rep. gr. 50 ; Assembly overview - lock
ed
carrier
byV gu
ara
ris nte
♦ Noise insulation; Assembly overview
autho
- noise insulation ⇒ Rep. eo
ra
gr. 50 ; Assembly overview - noise
ss insulation c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
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cial p
f inform
mer
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om
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c
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or
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 16
2.1 Assembly overview - assembly mount‐

ings
Engine assembly mountings
Specified torque
Bolt A 20 Nm + 90°
Bolt B 40 Nm + 90°
Bolt C 60 Nm + 90°
Gearbox assembly mounting

Specified torque olkswage es n
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Bolt A 40 Nmss a+ 90° ac
ce
e
Bolt B 60 Nm + 90°
nl
pt
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itte
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erm
ab
ility
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wit
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spec
es, in part or in w
t to the co
Pendulum support
Specified torque
rrectness of i
l purpos
Bolt A 40 Nm + 90°
Bolt B 100 Nm + 90°
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.

Caddy 2011 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 17
⇒ “1.2 Assembly overview - cylinder block”, page 19
⇒ “1.3 Removing and installing poly V-belt”, page 20
⇒ “1.4 Renewing crankshaft oil seal - belt pulley end”,
page 21
⇒ “1.5 Removing and installing sealing flange on pulley end”,
page 24
1.1 Assembly overview - poly V-belt drive

AG. Volkswagen AG d
agen oes
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1 - Poly V-belt pulley d by Vo gu
ara
rise nte
2 - Bolt utho eo
ra
a
❑ Renew afters removing
s c
ce
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un
❑ 10 Nm + 90°
pt
an
d
itte
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3 - Bolt
erm
ab
ility
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❑ 23 Nm
wit
is n
h re
4 - Tensioning element for poly
ole,
V-belt
spec
❑ Swing with open-end

spanner to slacken poly t to the co
V-belt. rrectne
5 - Bracket for ancillaries

❑ Observe tightening se‐
s
quence ⇒ page 18 .
s o
cial p
f i
6 - Bolt
nform
mer
❑ 23 Nm
atio
om
7 - Deflector plate
n
c
i
or
n thi
e
8 - Nut
t
sd
iva
o
pr
❑ 23 Nm
um
r
fo
en
ng
t.
yi
9 - Alternator
Co
Cop py
t.
❑ To facilitate attachment
rig
gh ht
yri by
of alternator, knock cop Vo
by lksw
back threaded bushes cted agen
Prote AG.
for alternator securing
bolts slightly.
❑ Removing and installing
⇒ Electrical system;
Rep. gr. 27 ; Alternator
10 - Bolt
quence ⇒ page 18 .
❑ If the bolts are Dacromet bolts (bolts have a greenish finish), they must be renewed after each removal.
❑ 45 Nm
11 - Bush
12 - Bolt
❑ 25 Nm
1. Cylinder block (pulley end) 17

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
13 - Air conditioner compressor byV
o gu
ara
ed
❑ Removing and installing ⇒ Heating,hoair conditioning system; Rep. gr. 87 ; Air conditioner
ris nte
eo compressor
aut ra
14 - Poly V-belt ss c
ce
e
nl
❑ Mark direction of rotation with chalk or felt pen before removing.
pt
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an
itte
❑ Check for wear.
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erm
ab
❑ Do not kink.
ility
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wit
❑ Removing and installing ⇒ page 20 , is n
h re
hole
spec
es, in part or in w
t to the co
Bolt-tightening sequence for ancillary bracket
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
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.
18 Rep. gr.13 - Crankshaft group

Caddy 2011 ➤
1.2 Assembly overview - cylinder block
1 - Knock sensor 1 - G61-

❑ Gold-plated contacts.
2 - Bolt
❑ The tightening torque in‐
fluences the function of
the knock sensor.
❑ 20 Nm
3 - Oil dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 76 .
4 - Bracket
❑ For ignition transformer
5 - Bolt
❑ 10 Nm
6 - Nut
❑ 10 Nm
7 - Bolt
❑ 10 Nm
8 - Bracket
9 - Bolt
❑ 6 Nm
10 - Oil filter bracket with at‐
tachments . Volkswagen AG
gen AG does
❑ Dismantling and assem‐ Volkswa not
bling ⇒ page 77 . ed
by gu
ara
ris nte
11 - Bolt ho eo
aut ra
ss c
❑ 15 Nm + 90°
ce
e
nl
pt
du
12 - Gasket
an
itte
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erm
❑ Renew after removing

ab
ility
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13 - Bolt
wit
, is n
h re
❑ 10 Nm
hole
spec
14 - Engine speed sender - G28-

es, in part or in w
t to the co
15 - Connection
16 - Bolt
rrectness of i
❑ 15 Nm
l purpos
17 - O-ring
nform
ercia
18 - Seal
m
at
om
io

n
c
in t
or
his
e
19 - Thermostat
at
do
riv
❑ Checking: heat thermostat in water.

p
cum
for
en
g
❑ Opening begins at approx. 85 °C.

n
t.
yi Co
op
❑ Ends at approx. 105 °C.
C py
t. rig
gh ht
yri
❑ Opening lift at least 7 mm. p by
o Vo
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
❑ Removing and installing ⇒ page 91 .
20 - Cylinder block
❑ Removing and installing sealing flange and flywheel ⇒ page 28 .
❑ Removing and installing crankshaft ⇒ page 31 .
❑ Dismantling and assembling pistons and conrods ⇒ page 34
21 - Coolant pipe seal
1.3 Removing and installing poly V-belt

Special tools and workshop equipment required
♦ Locking pin - T10060 A-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
Removing
rrectne
– Mark the direction of rotation of the poly V-belt.

ss
– Swing tensioning device in direction of arrow to relieve tension

o
cial p
f i
on poly V-belt.
nform
mer
atio
om
n
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.

Caddy 2011 ➤
– Lock tensioning element using locking pin - T10060 A- .

– Remove poly V-belt.
Installing
. Volkswagen AG
does gen AG
– Install in reverse order.
Vol
kswWhile doing so, note the
a
nfollowing:
ot
by gu
ara
ed nte
oris eo
th
Note s au ra
c
s
ce
le
un
pt
♦ When fitting poly V-belt, check the direction of belt rotation and
an
d
itte
make sure the belt is seated properly in the belt pulleys.
y li
erm
ab
ility
♦ For vehicles without air conditioning, put poly V-belt over al‐
ot p
ternator last.
wit
is n
h re
ole,
♦ For vehicles with air conditioning, put poly V-belt over air con‐
spec
ditioning compressor last.
t to the co
After completing repair, always:
rrectne
– Start engine and check that belt runs properly.
s
Belt drive without air conditioner compressor
s 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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Belt drive with air conditioner compressor

Specified torques
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 50 ; Assembly overview - noise insulation
1.4 Renewing crankshaft oil seal - belt pulley end

AG. Volkswagen AG d
agen oes
olksw not
y V gu
Caddy 2011 ➤ rise d b ara
nte
4-cylinder injection
autho
engine (1.6 l engine, BiFuel) - Edition 12.2015
eo
ra
ss c
ce
le
un
pt
equipment required
an
d
itte
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rm
ab
♦ Oil seal extractor - 3203-
pe
ility
ot
wit
♦ Counterhold tool - 3415-
, is n
h re
hole
♦ Assembly tool - T10053-
spec
es, in part or in w
t to the co
1331-
rrectness of i
1332-
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.
Removing
– Remove upper toothed-belt guard.
– Set camshaft pulley to TDC No. 1 cylinder by turning crank‐
shaft. Marking on camshaft pulley must align with arrow on
toothed-belt guard.
– Release tensioning roller and remove toothed belt from cam‐
shaft toothed-belt pulley.
– Turn crankshaft back slightly.

Caddy 2011 ➤
– Remove crankshaft toothed-belt pulley by locking the toothed-

belt pulley using counterhold - 3415- .
– To guide seal extractor, screw centre bolt into crankshaft up

to the stop by hand.
– Unscrew inner part of oil seal extractor - 3203- 9 turns (approx.
20 mm) from the outer part and lock in position with the knurled
screw.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
ss c
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le
un
pt
an
d
itte
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erm
– Lubricate threaded head of oil seal extractor - 3203- , place it
ab
ility
in position and, exerting firm pressure, screw it into the oil seal
ot p
wit
as far as possible.
is n
h re
ole,
– Loosen knurled screw and turn inner part against crankshaft
spec
until the oil seal is pulled out.
t to the co
Installing
– Remove oil residues from crankshaft journal with a clean cloth. rrectness o
cial p
f inform
mer
– Fit guide sleeve - T10053/1- onto crankshaft journal.

atio
om
n
c
– Slide dry oil seal over guide sleeve onto crankshaft journal.
i
or
n thi
te
sd
iva
o
pr
cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Press in seal using fitting sleeve - T10053- and bolt -

T10053/2- (M16 x 1.5 x 60) up to the stop.
lkswage es n
Vo ot g
– Fit crankshaftedtoothed-belt
by pulley and lock with counterhold
ua
ran -
3415- . hor is tee
ut or
a ac
ss
ce
le
Note
un
pt
an
d
itte
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erm
ab
♦ The contact surface between the toothed-belt pulley and the
ility
ot p
crankshaft must be free of oil.
wit
is n
h re
♦ The centre bolt must be renewed.
ole,
spec
♦ Thread and shoulder must be free of oil and grease.

t to the co
Installing toothed belt and adjusting valve timing ⇒ page 50 .
rrectne
Specified torques
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 48
ss o

cial p
f inform

mer

atio
om
n
c
i
or
1.5 Removing and installing sealing flange on pulley end

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.

Caddy 2011 ➤

equipment required
1331-
1332-
♦ Silicone sealant ⇒ Elec‐
tronic Parts Catalogue (ET‐
KA)
♦ Flat scraper
♦ Hand drill with plastic brush
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
Removing:
ot p
wit
, is n

h re
hole
spec

es, in part or in w
t to the co
– Set camshaft pulley to TDC No. 1 cylinder by turning crank‐

shaft. Marking on camshaft pulley must align with arrow on
toothed-belt guard.
rrectness of i

l purpos
shaft pulley.
nform
mercia
at
om
ion
c
in t
or
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ate
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Caddy 2011 ➤
– Remove crankshaft toothed-belt pulley by locking the toothed-

belt pulley using counterhold - 3415- .
– Drain off engine oil.
– Remove sump ⇒ page 73 .
– Unbolt front sealing flange.
– Remove sealing flange; if necessary, loosen using light blows
with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Cover oil seal with a clean cloth.
AG. Volkswagen AG d
agen oes
Note olksw not
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If seal is to be renewed, drive out seal. autho eo
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– Remove residual sealant on sealing flange using a rotating
an
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plastic brush (wear eye protection).
erm
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ility
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– Clean sealing surfaces. They must be free of oil and grease.
wit
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Installing
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Caddy 2011 ➤
– Cut off nozzle on tube at front marking (diameter of nozzle:

approx. 3 mm).
– Apply sealant bead of about 2…3 mm as shown -arrows- to
clean sealing surface of sealing flange.
Note
♦ Before applying sealant bead, cover sealing ring with a clean

cloth.
♦ The sealant bead must not be thicker than 2…3 mm, as oth‐
erwise excess sealant will enter the sump and obstruct the
strainer in the oil intake pipe.
♦ Observe expiry date of sealing compound.
♦ The sealing flange must be installed within 5 minutes after ap‐
plying the silicone sealant.
♦ When fitting sealing flange with oil seal installed, use guide
sleeve - T10053/1- .
♦ Sealing compound must dry for approx. 30 minutes after in‐
stallation. Only then fill with engine oil.
– Fit sealing flange immediately and lightly tighten all bolts.

– Tighten sealing flange securing bolts diagonally and alternate‐
ly.
– Remove excess sealant. AG. Volkswagen AG d
agen oes
– Fit sump ⇒ page 73 . olksw not
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– Install oil seal if necessary ⇒ page 21 .thor eo
au ra
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– Fit crankshaft toothed-belt pulley and lock with counterhold -
ce
le
un
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3415- .
an
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Note
wit
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♦ The contact surface between toothed-belt pulley and crank‐

spec
shaft must be free of oil.

t to the co
♦ The centre bolt must be renewed.

♦ Thread and shoulder must be free of oil and grease.
rrectne
Installing toothed belt and adjusting valve timing ⇒ page 50 .

ss o
Specified torques
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♦ ⇒ “1.1 Assembly overview - sump and oil pump”, page 71

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Caddy 2011 ➤
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 28 gen AG
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⇒ “2.2 Removing and installing
db
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Vo flange on gearbox side”,
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2.1 Assembly overview - cylinder block, gearbox endss c
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1 - Bolt
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❑ 15 Nm
ot p
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2 - Seal
h re
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spec
❑ PTFE oil seal:
❑ Identification: Without
t to the co
inner hose spring.
❑ Do not additionally oil or
rrectne
grease the oil seal seal‐
ing lip.
s
❑ Renew. ⇒ page 21 .
s o
cial p
f i
3 - Front sealing flange
nform
mer
❑ Must seat on dowel
atio
m
sleeves.
o
n
c
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thi
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⇒ page 24 .
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4 - Stud
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.
❑ 10 Nm
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5 - Cylinder block
by lksw
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crankshaft
⇒ page 31 .
❑ Dismantling and assem‐
bling pistons and con‐
rods ⇒ page 34
6 - Seal
7 - Bolt
❑ 100 Nm
8 - Bolt
❑ 60 Nm + 90°
9 - Flywheel
❑ Remove and install with counterhold tool - 3067-
10 - Intermediate plate
❑ Must seat on dowel sleeves.
❑ Do not damage or bend when assembling.
11 - Sealing flange with oil seal
Removing and installing ⇒ page 29

Caddy 2011 ➤
2.2 Removing and installing sealing flange

on gearbox side
AG. Volkswagen AG d
Special tools and workshop equipment required ksw
agen oes
not
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♦ Fitting tool - T10122- ised ara
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Removing
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– Remove gearbox ⇒ Rep. gr. 34 .

– Remove flywheel.
nform
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– Remove sump ⇒ page 73 .

m
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– Unscrew sealing flange -arrows-.
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Do not also oil or grease the oil seal sealing lip.
AG.

– Remove oil residues from crankshaft journal with a clean cloth.
– Put together assembly sleeve - T10122/1- and assembly
sleeve - T10122/2- .
– Push sealing flange -A- onto the assembly sleeves with its ex‐
terior surface.
– Separate assembly sleeves.
2. Cylinder block, gearbox end 29

Caddy 2011 ➤
– Place sealing flange -A- with the assembly sleeve - T10122/2-

on the crankshaft and push the sealing flange onto the crank‐
shaft journal.
– Tighten securing bolts -arrows-.

– Fit sump ⇒ page 73 .
Specified torques
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
28
AG. Volkswagen AG d
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Caddy 2011 ➤
3 Crankshaft
⇒ “3.1 Assembly overview - crankshaft”, page 31
⇒ “3.2 Identification of crankshaft bearings”, page 32
⇒ “3.3 Removing and installing sender wheel”, page 33
⇒ “3.4 Crankshaft dimensions”, page 33
3.1 Assembly overview - crankshaft
Note
♦ Before removing the crankshaft, ensure that a suitable surface

for storing the crankshaft is prepared to ensure that sender
wheel ⇒ Item 8 (page 32) is not damaged or lies against any
other item.
♦ When carrying out repairs, secure engine to engine and gear‐
box support - VAS 6095- .
1 - Oil pump
2 - Bolt
❑ 15 Nm
3 - Chain sprocket
❑ For oil pump drive.
4 - Bearing shells 1, 2, 3, 4 and
5 n AG. Volkswagen AG do
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❑ For bearing cap without byV
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❑ For cylinder block with au or
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❑ Do not interchange
du
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used bearing shells

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(mark).
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❑ Classification for order‐

wit
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ing spare parts

h re
hole
⇒ page 32 .
spec
es, in part or in w
5 - Bolt
t to the co

❑ Threaded along com‐
rrectness of i
plete length.
l purpos
❑ Tighten to 40 Nm when
measuring crankshaft
radial clearance.
nform
ercia
❑ 40 Nm + 90°
m
at
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6 - Bearing cap
on
c
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❑ Bearing cap 1: poly V-

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❑ Bearing shell retaining

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and bearing caps must Cop py
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7 - Bearing shell 3
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Prote AG.
❑ Do not interchange used bearing shells (mark).
3. Crankshaft 31
Caddy 2011 ➤
8 - Sender wheel
❑ For engine speed sender - G28- .
❑ Always renew sender wheel if securing bolts have been unscrewed
❑ Can only be installed in one position as holes are offset
9 - Bolt
❑ 10 Nm + 90°
10 - Crankshaft
❑ Axial clearance:
❑ New: 0.07…0.23 mm AG. Volkswagen AG d
agen oes
❑ Wear limit: 0.30 mm olksw not
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❑ Checking radial clearance
orise with Plastigage: nte
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❑ New: 0.01…0.04 ss a mm
u ra
c
❑ Wear limit: 0.07 mm
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nl
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❑ Do not rotate crankshaft when checking radial clearance.
itte
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❑ Crankshaft dimensions ⇒ page 33 .
ility
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11 - Thrust washer
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❑ For cylinder block, bearing 3
hole
spec
❑ Lettering faces mounting bracket
es, in part or in w
3.2 Identification of crankshaft bearings t to the co

rrectness of i
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Letters on the lower sealing surface of the cylinder block indicate

which bearing thickness is to be used at each position.
nf
ercia
Arrow points in direction of travel.

orm
m
Upper bearing shells of the proper thickness are allocated to the

atio
m
cylinder block in the factory. Coloured dots are used to identify

o
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the thickness of the bearing shells.

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R = Red
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B = Blue
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Note
♦ If the coloured marks are no longer readable, use blue bearing

shells.
♦ Lower crankshaft bearing shells with “yellow” coloured marks
are always supplied as spare parts.

Caddy 2011 ➤
3.3 Removing and installing sender wheel

– Renew sender wheel -2- each time bolts -1- are loosened.
Note
♦ The second time the bolts are tightened, the contact points in
the sender wheel for the countersunk heads are deformed so
much that the bolt heads seat on the crankshaft -3-, -arrows-
and the sender wheel is loose under the bolts.
♦ The sender wheel can only be installed in one position, the
holes are offset.
3.4 Crankshaft dimensions

(Dimensions in mm)
Honing dimen‐ Crankshaft bearing Conrod
sion journal diameter journal diameter
Basic dimension 48.00 -0.017 42.00 -0.022
-0.037 -0.042
Stage I 47.75 -0.017 41.75 -0.022
-0.037 -0.042
Stage II 47.50 -0.017 41.50 -0.022
-0.037 -0.042
Stage III 47.25 -0.017 41.25 -0.022
-0.037 -0.042
AG. Volkswagen AG d
agen oes
olksw not
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3. Crankshaft 33
Caddy 2011 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 34
⇒ “4.2 Bearing shells - installation position.”, page 35
⇒ “4.3 Separating new conrod”, page 35
⇒ “4.4 Checking piston and cylinder bore”, page 36
⇒ “4.5 Piston and cylinder dimensions”, page 37
4.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
remove and install.
❑ “TOP” faces towards
piston crown.
❑ Checking ring gap
⇒ page 36 . AG. Volkswagen AG d
agen oes
ksw
❑ Checking ring-to-groove
by Vol not
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ara
clearanceris⇒
e page 36 .
d
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2 - Piston ss au ra
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❑ Mark installation posi‐
ce
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tion and cylinder num‐

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❑ Arrow on piston crown

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points to poly V-belt pul‐

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ley end
ole,
spec
❑ Fit using piston ring

clamp
t to the co
❑ Checking ⇒ page 37 .
3 - Piston pin
rrectne
❑ If difficult to remove,
heat piston to 60 °C.
ss o
❑ Remove and install us‐

cial p
f in
ing drift - VW 222 A-

form
mer
4 - Circlip
atio
om
n
c
5 - Conrod
i
or
n thi
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❑ Renew as set only.

sd
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❑ Mark cylinder number

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-B-. yi
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❑ Installation position:
C py
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markings -A- face to‐
ht
pyri by
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wards poly V-belt pulley
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end. Prote AG.
6 - Bearing shell
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally
❑ Axial clearance:
❑ New: 0.05…0.31 mm
❑ Checking radial clearance with Plastigage:
❑ New: 0.01…0.06 mm

Caddy 2011 ➤
❑ Do not rotate crankshaft when checking radial clearance.
❑ Note installation position ⇒ page 35 .
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 37 .
❑ Piston and cylinder dimensions ⇒ page 37 .
8 - Conrod bearing cap
❑ Note installation position.
❑ Due to the cracking method used to separate the bearing cap from the conrod during manufacture, the
caps only fit in one position and only on the associated conrod.
9 - Conrod bolt
❑ Oil threads and contact surface
❑ To measure radial clearance, tighten to 30 Nm but not further.
❑ 30 Nm + 90°
4.2 Bearing shells - installation position.

Bearing shell -1- with oil hole -arrow- for conrod.
Bearing shell -2- without oil hole for conrod bearing cap
– Position bearing shells in centre of conrod and conrod bearing
cap when fitting. en AG. V
olkswagen AG
ag does
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Distance -a- must be identical on both sides. gu
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4.3 Separating new conrod

h re
hole
spec
On new conrods it is possible that the breaking point is not fully

es, in part or in w
separated. If the conrod bearing cap cannot be removed by hand,

t to the co
proceed as follows:
– Mark the cylinder to which the conrod belongs
rrectness of i
⇒ Item 5 (page 34) .

l purpos
– Lightly clamp the conrod in a vice using aluminium vice

clamps, as shown in the picture.
nf
ercia
orm
m
Note
atio
om
n in
or c
♦ Only clamp conrod lightly so as not to damage it.

thi
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sd
iva
♦ Conrod is clamped below the dashed line.

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– Unscrew both bolts -arrows- about 5 turns. t. Cop py
rig
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pyri by
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Prote AG.
4. Pistons and conrods 35

Caddy 2011 ➤
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap in -direction of arrow- until it is loose.
4.4 Checking piston and cylinder bore

Checking piston ring gap

♦ Feeler gauges
– Push ring squarely from above down into cylinder bore to ap‐
prox. 15 mm from bottom end of cylinder.
Piston ring Ring gap
New Wear limit
. Volkswagen AG
Compression rings mm 0.20 …sw0.40agen
AG
0.8 does
olk not
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Oil scraper ring mm e0.25
d b … 0.50
y 0.8 gu
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Checking ring-to-groove sclearance
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♦ Feeler gauges
nform
ercia
– Clean annular groove before check.

m
at
om
ion
Piston ring Clearance

c
in t
or
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New Wear limit

at
do
priv
Compression rings mm 0.06 … 0.09 0.20

cum
for
en
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Oil scraper ring mm 0.03 … 0.06 0.15

n
t.
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Cop py
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by
36
cted agen
Prote AG.
Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
Checking piston

♦ Micrometer 75 - 100 mm - VAS 6071-
– Measure approx. 10 mm from lower edge of skirt, at 90° to
piston pin axis.
Deviation from nominal dimension max. 0.04 mm
Checking cylinder bores
AG. Volkswagen AG d
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es, in part or in w
♦ Cylinder gauge - VAS 6078-

t to the co
– Take measurements at 3 positions in both lateral direction

-A- and longitudinal direction -B-.
rrectness of i
Difference between actual and nominal diameter max. 0.08 mm.

l purpos
Note
nform
mercia
Cylinder bores must not be measured when cylinder block is

a
com
tio
mounted on engine and gearbox support - VAS 6095- , because

n in
r
the measurements may be incorrect.

te o
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iva
do
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4.5 Piston and cylinder dimensions

um
fo
en
ng
t.
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op
Honing dimen‐ Piston diameter Cylinder bore di‐
C py
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rig ht
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Basic dimension mm 80.9651) cted
81.01
agen
Prote AG.
1) Dimensions without graphite coating (thickness 0.02 mm). Graphite coating

wears away.
4. Pistons and conrods 37

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
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15 – Cylinder head, valve gear
Vol
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1 Cylinder head
s
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nl
pt
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itte
⇒ “1.1 Assembly overview - cylinder head”, page 38
y li
erm
ab
⇒ “1.2 Checking cylinder head for distortion”, page 39
ility
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⇒ “1.3 Removing and installing cylinder head”, page 40
h re
hole
spec
⇒ “1.4 Checking compression”, page 45
es, in part or in w
t to the co
1.1 Assembly overview - cylinder head
rrectness of i
1 - Bolt
l purpos
❑ Apply locking fluid when

inserting.
nform
ercia
❑ 23 Nm
m
2 - Camshaft pulley
at
om
ion
c
3 - Bolt
in t
or
his
te
❑ Use counterhold tool -

a
do
riv
3415- to loosen and

p
cum
or
tighten.
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❑ 100 Nm t. Cop py
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4 - Bolt p by
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Prote AG.
inserting.
❑ 10 Nm
5 - Rear toothed-belt guard
6 - Woodruff key
7 - Seal
8 - Bolt
❑ 10 Nm
9 - Breather connection
10 - Special bolt
❑ Renew if damaged or
leaking.
❑ 9 Nm
11 - Gasket
❑ Renew if damaged or
leaking.
12 - Cap
13 - Cylinder head cover
❑ To remove the bolts, loosen them from outside inwards.
❑ To install the bolts, tighten them from inside outwards.
14 - Gasket for cylinder head cover
❑ Renew if damaged or leaking.
❑ Press into spacer sleeves of ⇒ Item 10 (page 38) .
15 - Cylinder head bolt
38 Rep. gr.15 - Cylinder head, valve gear

Caddy 2011 ➤
❑ Follow sequence when loosening and tightening ⇒ page 40
16 - Bolt
❑ 10 Nm
17 - Hall sender - G40-
18 - O-ring
19 - Cylinder head
❑ After replacement, refill system with fresh coolant
❑ Check for distortion ⇒ page 39 .
❑ Reworking dimension ⇒ page 57
❑ Removing and installing ⇒ page 40
20 - Connection
21 - Bolt
❑ 10 Nm
22 - O-ring
23 - Cylinder head gasket
❑ Installation position: part number faces cylinder head and must be readable from the inlet side
❑ After replacement, refill system with fresh coolant Volkswa AG. gen AG
agen does
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1.2 Checking cylinder head for distortion au
tho
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Max. permissible distortion: 0.1 mm
ce
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itte
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1. Cylinder head 39
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Caddy 2011 ➤ auth or
ac
ss
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nl
pt
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1.3 Removing and installing cylinder head
itte
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hole
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es, in part or in w
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1332-
♦ Hose clip pliers - VAS
rrectness of i
6362- l purpos
♦ Guide pins - 3450/2A-
♦ Removal tool - 3450/3-
nform
ercia
♦ Allen key, long reach -

m
T10070-
at
om
ion
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do
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Prote AG.

Caddy 2011 ➤

• The engine must be no more than warm to touch.
Removing
Note
♦ If an exchange cylinder head is installed, all the contact sur‐

faces between the supporting elements, roller rocker fingers
and the running surfaces of the camshaft must be oiled before
the cylinder head cover is fitted.
olkswagen AG
en AG. V
♦ The plastic packing pieces for protecting the open
olks valves must
wag does
not
not be removed until immediately beforeedfitting by V
the cylinder gu
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head. horis nte
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If the cylinder head is replaced, allss the coolant in the system
a
♦ c
must also be renewed.
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Caution
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es, in part or in w
tions:
t to the co
rrectness of i
out.
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nform
mercia
a
com
ti
– First check whether a coded radio is fitted. If so, obtain anti-
on in
theft coding.
r
te o
thi
s
iva
– Disconnect battery earth strap with ignition switched off ⇒ do

r
rp
c
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
um
fo
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g
ing battery .
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t.
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– Now drain coolant ⇒ page 81 .
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WARNING Prote AG.
Fuel supply line is pressurised. Wear eye protection and pro‐

tective clothing to avoid possible injury and skin contact. Before
loosening hose connections, wrap a cloth around the joint.
connection.
– Remove intake manifold ⇒ page 151 .
Note
Seal intake ports in intake manifold lower part with a clean cloth.
1. Cylinder head 41
Caddy 2011 ➤
– Unscrew coolant distributor housing -arrows-.
AG. Volkswagen AG d
agen oes
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un
pt
– Pull off coolant hose -arrow- at the rear breather connection
an
d
itte
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on the cylinder head.
rm
ab
pe
ility
– Pull off or disconnect all the other electrical connections as
ot
wit
, is n
necessary from the cylinder head and lay open.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Unbolt bracket for exhaust system -arrows-.

m
a
– Release front exhaust pipe from exhaust manifold and pull it
com
tion in
off.
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te o
thi

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cum

fo
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Prote AG.
– Set camshaft pulley to TDC No. 1 cylinder mark by turning

crankshaft. The mark on the camshaft pulley must align with
the arrow on toothed-belt guard.
– Undo securing nut of tensioning roller and remove toothed belt
from camshaft toothed-belt pulley.
– Remove securing nut and washer from the tensioning roller.

Caddy 2011 ➤
– Remove camshaft. When undoing camshaft pulley bolt, hold

with the counterhold - 3415- .
– Remove Woodruff key from camshaft.
– Unbolt toothed-belt guard rear from the cylinder head

-arrows-.
– Remove cylinder head cover.
AG. Volkswagen AG d
agen oes
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spec
t to the co
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cial p
f inform
mer
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c
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Prote AG.
1. Cylinder head 43
Caddy 2011 ➤
– Undo socket head bolts using Polydrive key agen

-A3452-
G. Volksor
waglong-
en AG
does
reach Allen key - T10070- in the sequence
Volksw given and then not
gu
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remove completely. se
d b ara
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ho
– Lift the cylinder head slightly
au and remove it from the engine
t or
ac
past the side of the toothed-belt
ss guard.
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Note
erm
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♦ Toothed-belt tensioning roller stays on the engine bracket.
, is n
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hole
♦ The cylinder head must be guided carefully to prevent dam‐
spec
age.
es, in part or in w
t to the co
Installing
rrectness of i
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Note
nf
ercia
or
♦ There must be no oil or coolant in the cylinder head bolt pock‐
m
m
atio
ets in the cylinder head.
om
n in
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♦ Do not remove new cylinder head gasket from its packing until
thi
te
sd
immediately before installing.
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♦ Handle new gasket with extreme care. Damage will cause
o
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leakage.
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♦ Renew cylinder head bolts. gh ht
pyri by
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cted agen
– Place clean cloths in cylinders so that no dirt or emery cloth Prote AG.
particles can get in between cylinder wall and piston.

– Also prevent dirt and emery cloth particles from getting into
coolant.
– Carefully clean sealing surfaces of cylinder head and cylinder
block. Ensure that surfaces are not scored or scratched (if
abrasive paper is used, grade must not be less than 100).
– Carefully remove metal particles, emery residue and cloths.
– If crankshaft has turned in the meantime, position piston of No.
1 cylinder at TDC and turn crankshaft back slightly.
– To centre, screw guide pins - 3450/2A- into outer threaded

holes on the exhaust side.
– Fit the new cylinder head gasket in position. Inscription (Part
No.) must be readable.
Note
Tensioning roller must be pushed onto the studs when fitting the
cylinder head.
– Fit cylinder head, screw in 8 remaining cylinder head bolts and

tighten by hand.
– Remove guide pins through bolt holes using the removal tool
- 3450/3- . To do this, turn removal tool anti-clockwise until pins
are free.
– Now insert both remaining cylinder head bolts and tighten
them hand-tight.

Caddy 2011 ➤
– Tighten cylinder head bolts in tightening sequence as follows:

Stage Tighten
1 – Tighten to 40 Nm using torque wrench.
2 – Turn 90° further (1/4 turn) using a rigid wrench.
3 – Turn 90° further (1/4 turn) using a rigid wrench.
Note
When camshaft is turned, crankshaft must not be at TDC. Danger

of damage to valves and piston crowns.
– Install toothed belt and adjust valve timing ⇒ page 50 .

Specified torques
♦ ⇒ “1.1 Assembly overview - cylinder head”, page 38
♦ ⇒ “3.1 Assembly overview - intake manifold”, page 148
1.4 Checking compression
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by
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Prote AG.
1. Cylinder head 45
Caddy 2011 ➤

equipment required
♦ Spark plug socket and ex‐
tension - 3122 B-
♦ Puller - T10112-
1331-
♦ Compression tester - V.A.G
1763- with adapter - V.A.G
1763/6-
AG. Volkswagen AG d
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Test specification:
rrectness of i
• Engine oil temperature must be at least 30°C.

l purpos
• Voltage supply OK.

nform
ercia
• Observe safety precautions ⇒ page 3 .

m
at
Procedure
om
ion
c
in t
r
– Pull off connector from ignition transformer - N152- .

o
his
ate
do
riv
– Pull off connector to the outer injectors.

p
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pyri by
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by
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Prote AG.

Caddy 2011 ➤
– Pull off spark plug connector using puller - T10112- .

– Unscrew spark plugs with spark plug spanner - 3122 B- .
– Check compression using compression tester - V.A.G 1763-
and adapter - V.A.G 1763/6- .
Note
Using the compression tester ⇒ Operating instructions

AG. Volkswagen AG d
agen oes
– Have starter actuated
yV
oby
lkswa second mechanic. not
gu
b ara
ed
– Operate starterhorisuntil tester shows no further pressure in‐ntee
crease. au
t or
ac
ss
Compression pressures:
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New Wear limit Difference between
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bar pressure bar pressure cylinders
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bar pressure
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10.0 … 13.0 7.0 max. 3.0
hole
spec
es, in part or in w
– After completing work, clear event memory of engine control
t to the co
unit since faults will have been saved from the connectors be‐
ing pulled off ⇒ Vehicle diagnostic tester.
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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cum
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en
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Prote AG.
1. Cylinder head 47
Caddy 2011 ➤ agen
AG. Volkswagen AG d
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4-cylinder injection engine (1.6 l engine,
by Vol
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2 Toothed belt drive
ac
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⇒ “2.1 Assembly overview - toothed belt drive”, page 48
an
itte
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ab
⇒ “2.2 Removing and installing toothed belt guard”, page 49
ility
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⇒ “2.3 Removing and installing toothed belt”, page 50 , is n
h re
hole
⇒ “2.4 Checking semi-automatic toothed belt tensioner”,
spec
page 55
es, in part or in w
t to the co
2.1 Assembly overview - toothed belt drive
rrectness of i
1 - Bolt
l purpos
❑ Insert with locking fluid.

❑ 10 Nm
nform
ercia
2 - Centre toothed-belt guard

m
at
om
io
3 - Engine bracket
n
c
in t
or
his
e
4 - Bolt
at
do
priv
c
❑ 45 Nm
um
for
en
ng
t.
5 - Upper toothed-belt guard
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⇒ page 49 .
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6 - Nut
Prote AG.
❑ 23 Nm
7 - Washer
8 - Semi-automatic belt ten‐
sioner
9 - Bolt
3415- to loosen and
tighten.
❑ 100 Nm
10 - Camshaft pulley
❑ Locked in installation
position by Woodruff
key
⇒ Item 14 (page 48) .
11 - Bolt
inserting.
❑ 10 Nm
12 - Bolt
❑ Apply locking fluid when inserting.
❑ 23 Nm
13 - Rear toothed-belt guard
14 - Woodruff key
❑ Check for secure seating.
15 - O-ring

Caddy 2011 ➤
16 - Coolant pump
17 - Bolt
❑ 15 Nm
18 - Crankshaft toothed-belt pulley
❑ Contact surface between toothed-belt pulley and crankshaft must be free of oil.
❑ Fitting possible in one position only.
19 - Bolt
❑ Do not oil.
n AG. Volkswagen AG
❑ Use counterhold tool ksw
a-ge3415- to loosen and
doestighten.
not
Vol
❑ 90 Nm + 90° ed
by gu
ara
is nte
or
20 - Toothedabelt
ut
h eo
ra
s c
❑ Marks direction of rotation with chalk or felt pen before removing.
ce
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pt
❑ Check for wear.
du
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ility
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21 - Lower toothed-belt guard
wit
, is n
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22 - Bolt
hole
spec
❑ Apply locking fluid when inserting.
es, in part or in w
t to the co
❑ 10 Nm
rrectness of i
2.2 Removing and installing toothed belt
l purpos
guard
nform
ercia
– Position securing bolt -1- vertical.

m
– Press the retaining lugs -arrow- upwards and remove the

at
om
io
toothed-belt guard.
n
c
in t
or
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e
Installing
at
do
priv
Install in reverse order.

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for
en
ng
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Vo
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by c lksw
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Prote AG.
2. Toothed belt drive 49

Caddy 2011 ➤
2.3 Removing and installing toothed belt

equipment required
♦ Support bracket - 10 - 222
A- with adapter - 10 - 222
A /30-
♦ 2-hole pin wrench -
T10020-
1331-
1332-
AG. Volkswagen AG d
agen oes
olksw not
V gu
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pt
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ab
ility
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wit
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
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om
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or c
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sd
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Vo
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by c lksw
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Prote AG.

Caddy 2011 ➤
♦ Adapter - 10-222A/30-
♦ Bracket - 10-222A/32-
Removing
– Remove locking pin - T10060 A- .
– Pull off top hose from coolant expansion tank.
– Undo expansion tank and lay it to one side.
olkswagen AG
en AG. V
– Remove upper toothed-belt
olks
wag guard. does
not
y V gu
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rise nte
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– Places asupport bracket - 10-222A- with adapters - 10-222A/30-
ut ra
c
behind bonnet stay.
s
ce
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nl
pt
du
– Engage bracket - 10-222A/32- with shackle - 10 - 222 A /32-1- .
an
itte
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erm
ab
– Remove lower noise insulation ⇒ General body repairs, ex‐
ility
ot p
terior; Rep. gr. 50 ; Body - front; Noise insulation .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove vibration damper/poly V-belt pulley.

– Remove centre and lower parts of toothed-belt guard.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t. rig
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by
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Prote AG.
– Unscrew bottom bolt -1- from the engine bracket.

Caddy 2011 ➤
– Remove securing bolts from assembly mounting/engine

bracket -arrows- and remove complete assembly mounting.
Caution
AG. Volkswagen AG d
agen oes
olksw not
When raising engine using support bracket - 10-222A-
ed by V , ensure gu
ara
that no components or hoses are damaged, horisstrained or torn nte
eo
off. s aut ra
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pt
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an
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ab
ility
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– Lift engine with support bracket - 10 - 222 A- until both upper
h re
hole
bolts -2- and -3- of engine bracket can be undone and re‐
spec
moved.
es, in part or in w
t to the co
– Remove engine bracket upwards.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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at
do
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crankshaft. The mark on the camshaft toothed-belt pulley must

p
cum
or
align with the arrow on the toothed-belt guard.

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en
ng
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– Mark direction of rotation of toothed belt. . Cop py
rig
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rig
– Loosen tensioning roller and remove toothed belt. py by
co Vo
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agen
Prote AG.
Installing
Note
♦ When camshaft is turned, crankshaft must not be at TDC.

Danger of damage to valves and piston crowns.
♦ The engine must be no more than warm to touch.
– Place toothed belt on crankshaft pulley and coolant pump (ob‐

serve direction of rotation).

Caddy 2011 ➤
– Line up mark on camshaft toothed belt pulley with mark on

toothed-belt guard.
– Fit centre and lower toothed-belt guard.
n AG. Volkswagen A ge G do
swa es
– Fit poly V-belt pulley/vibration
by
Vol
k
damper using new bolts.
not
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es, in part or in w
t to the co
– Set crankshaft on the vibration damper to TDC Cylinder 1
rrectness of i
-arrow-.
l purpos
– Fit toothed belt to tensioning roller and camshaft toothed-belt

pulley.
nform
mercia
a
com
tion in
r
te o
thi
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iva
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Note cted agen
Prote AG.
Check that tensioning roller is seated correctly in the cylinder

head.

Caddy 2011 ➤
– Tighten toothed belt. To do this, turn 2-hole pin wrench -

T10020- on eccentric to left (direction of arrow) until pointer
-2- is above notch -1- (toothed belt over-tensioned).
Note
Repeat this work step (over-tension toothed belt) 5 times so that

the toothed belt settles.
– Then reduce tension on toothed belt until notch -1- and pointer
-2- align.
– Tighten securing nut.
– Turn crankshaft 2 full revolutions in direction of rotation until
engine is again at TDC No. 1 cylinder. It is important that the
last 45° rotation (1/8 turn) is performed without interruption.
– Check toothed belt tension again. Specification: pointer and
notch align.
– Check valve timing again.
If the markings do not align:
– Repeat valve timing adjustment.
– Attach engine bracket to cylinder block from above and tighten
both upper bolts.
– Lower engine to installation position.
– Install lower bolt, and tighten it.
– Install complete engine assembly mounting.
– Secure engine assembly mounting with new bolts to engine

bracket -arrows-. To do so, bring surfaces into contact using
support bracket - 10 - 222 A- .
– Remove support bracket - o10
lksw- 222 A- .
age es n
ot g
V
by ua
– Fit upper toothed-belt
ris guard.
ed ran
tee
tho or
– Install poly V-belt
ss
au ⇒ page 20 . ac
ce
le
– Fit coolant expansion tank.

un
pt
an
d
itte
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– Install lower noise insulation ⇒ General body repairs, exterior;

erm
ab

ility
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Specified torques
h re
ole,

spec
t to the co

rrectne

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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cum
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Cop py
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py by
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54
cted agen
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
Caddy 2011 ➤
2.4 Checking semi-automatic toothed belt

tensioner
Installation position
• The retainer -arrow- must be in the notch in the cylinder head.
Test procedure agen
AG. Volkswagen AG d
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• The engine must be no more than warm to touch. byV gu
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– Set engine to TDC No. 1 cylinder. aut
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– Press toothed belt with force using your thumb. The pointer
t to the co
-2- must move.
– Release toothed belt and turn crankshaft 2 full revolutions in
rrectness of i
direction of rotation until engine is again at TDC No. 1 cylinder.
It is important that the last 45° rotation (1/8 turn) is performed
l purpos
without interruption.
– The tensioning roller must return to its initial position. (Notch
nform
ercia
-1- and pointer -2- align again.)

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Check using a mirror.
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Caddy 2011 ➤
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 56
⇒ “3.2 Removing and installing camshaft oil seal”, page 58
⇒ “3.3 Removing and installing camshaft”, page 60
⇒ “3.4 Measuring axial play of camshaft”, page 64
⇒ “3.5 Removing and installing valve stem seals”, page 64
⇒ “3.6 Checking hydraulic compensation elements”, page 66
3.1 Assembly overview - valve gear
Note
♦ Cylinder heads which have cracks between the valve seats or

between a valve seat insert and the spark plug thread can be
used further without reducing service life, provided the cracks
do not exceed a maximum of 0.3 mm in width, or when no more
than the first 4 turns of the spark plug thread are cracked.
♦ Cylinder head and retaining frame must only be renewed to‐
gether.
1 - Bolt
3415- to loosen and
tighten.
AG. Volkswagen AG d
agen
❑ 100 Nm olksw
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not
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2 - Camshaft pulley orise nte
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3 - Seal ss a c
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❑ Renew. ⇒ page 58 .
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4 - Woodruff key
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5 - Nut
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❑ 23 Nm
h re
hole
spec
6 - Retaining frame
es, in part or in w
❑ The reworking of seal‐

t to the co
ing surfaces is not per‐

mitted
rrectness of i
❑ With integrated cam‐

shaft bearings
l purpos
❑ Bearing 1 at poly V-belt

pulley
nf
ercia

rm
m
quence of camshaft
atio
m
bearings ⇒ page 60
o
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or c
❑ Carefully apply sealant

thi
te
sd
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as per ⇒ Electronic
iv
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Parts Catalogue (ETKA)

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to sealant groove and

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ng
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lower sealing surface
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7 - Camshaft
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❑ Checking radial clear‐ Prote
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agen
ance with Plastigage;
wear limit: 0.1 mm.

Caddy 2011 ➤
❑ Runout: max. 0.04 mm
❑ Checking axial clearance ⇒ page 64 .
8 - Roller rocker finger
❑ Do not interchange.
❑ Check roller bearing.
❑ Oil contact surface.
❑ When installing, secure to supporting element using securing clip.
9 - Support element
❑ Do not interchange.
❑ With hydraulic valve clearance compensation.
❑ Oil contact surface.
10 - Cotters
11 - Valve spring plate
wage es n
12 - Valve spring yV
olks ot g
ua
d b
❑ Cylinder head o
ir seremoved: Remove and install using valve
ran
teespring compressor - 2037- .
th or
❑ Cylinder shead
au installed: ⇒ page 64 ac
s
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13 - Valve stem seal

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❑ Renew. ⇒ page 64 . an
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14 - Valve guide ab
ility
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15 - Cap
spec
es, in part or in w
❑ Install flush
t to the co
❑ To remove, pierce rubber centre with a screwdriver and lever out.

16 - Cylinder head
rrectness of i
❑ The reworking of camshaft-side sealing surfaces is not permitted

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❑ Reworking valve seats ⇒ page 68 .

17 - Valves
nf
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or
❑ Do not rework, only lapping-in is permitted.

m
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❑ Valve dimensions ⇒ page 70

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Reworking cylinder head sealing surface

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Cylinder head reworking dimension: a = at least 132.9 mm
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3. Valve gear 57
Caddy 2011 ➤
3.2 Removing and installing camshaft oil seal

equipment required
♦ Fitting sleeve - 3265-
♦ Oil seal extractor - 2085-
1331-
1332-
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spec
Removing
t to the co

crankshaft. Mark on camshaft pulley must align with arrow on
rrectne
toothed-belt guard.
s

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shaft pulley.
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Prote AG.

Caddy 2011 ➤
– Remove camshaft. When undoing camshaft pulley bolt, hold

with the counterhold - 3415- .
– Screw camshaft toothed-belt pulley securing bolt into cam‐
shaft up to stop.
– Unscrew inner part of oil seal extractor - 2085- 2 turns (approx.
3 mm) from the outer part and lock in position with the knurled
screw.
– Lubricate threaded head of oil seal extractor, place it in posi‐

tion and, exerting firm pressure, screw it into oil seal as far as
possible.
– Loosen knurled screw and turn inner part against camshaft
until oil seal is pulled out.
– Clamp flats of oil seal extractor in vice. Remove oil seal with
pliers.
Installing
Installation is carried
waout
gen Ain
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Prerequisiteed by ara
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• Theautpistons
h
must not be positioned at TDC. ra
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– Slide oil seal over guide sleeve - T10071/1- .

un
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– Remove guide sleeve.

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– Press in seal up to stop using fitting sleeve - 3265- and bolt -

T10071/2- .
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♦ Put a large, commercially available washer M12 under bolt to

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avoid wear to fitting sleeve.

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– Insert Woodruff key in camshaft.
3. Valve gear 59
Caddy 2011 ➤
– Install camshaft pulley. When tightening camshaft toothed belt

pulley bolt, hold with counterhold - 3415- .
Install toothed belt ⇒ page 50 .
Specified torques
3.3 Removing and installing camshaft

equipment required
♦ Fitting sleeve - 3265-
1331-
1332-
♦ Sealant ⇒ Electronic Parts
Catalogue (ETKA)
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ion
c
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or
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ate
do
priv
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for
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Prote AG.

Caddy 2011 ➤
Removing
Note
♦ The sealing surfaces on the bottom of the retaining frame and

top of the cylinder head must not be reworked.
♦ The camshaft bearings are integrated into the cylinder head
and the retaining frame. The toothed belt must be relieved of
tension before the retaining frame is removed.
♦ If retaining frame has been loosened, the camshaft seal and
the cover at rear must be renewed.
– Remove intake manifold ⇒ page 151 .
Note
Seal intake ports in intake manifold lower part with a clean cloth.

crankshaft. Mark on camshaft pulley must align with arrow on
toothed-belt guard.
shaft pulley.
AG. Volkswagen AG d
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ab
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– Remove camshaft. When undoing the camshaft pulley bolt,

wit
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hold with the counterhold - 3415- .

h re
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spec

es, in part or in w
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– Undo the cylinder head cover bolts from outside inwards.

rrectness of i
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do
priv
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for
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t.
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rig ht
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Prote AG.
3. Valve gear 61
Caddy 2011 ➤
– Unbolt toothed-belt guard rear from the cylinder head

-arrows-.
– Unscrew nuts from bearings 5, 1 and 3. Then undo bearings
2 and 4 alternately and diagonally.
AG . Volkswagen AG
– Remove retaining frame.
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– Carefully removeised camshaft upwards and lay aside on
b aclean
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surface. uth or tee
or
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– Remove the roller rocker finger with the support elements.
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Place on a clean surface.

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– Ensure that roller rocker fingers and supporting elements are
erm
ab
not interchanged.
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– Remove old sealant from the retaining frame groove -arrow-
hole
and from the sealing surfaces.
spec
es, in part or in w
t to the co
– Prevent dirt and sealant residues from entering cylinder head.
Installing
rrectness of i
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Prerequisites
• Sealing surfaces must be free of oil and grease.
nform
ercia
• When retaining frame or camshaft is installed, No. 1 cylinder

m
at
cams must point upwards.
om
ion
c
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• The pistons must not be positioned at TDC.

o
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ate
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– Install supporting elements in cylinder head and fit respective

p
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roller rocker finger onto respective valve stem end or support‐

for
en
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ing element.
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– Ensure that all roller rocker fingers contact valve stem ends py by
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-1- correctly and that they are clipped into their respective
by c lksw
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support elements -2-.
Prote AG.
– Oil running surfaces of the camshaft.

Caddy 2011 ➤
– Carefully lay camshaft in camshaft bearing of cylinder head in

position for TDC No. 1 cylinder.
– Apply an even, slightly raised bead of sealant ⇒ Electronic
Parts Catalogue (ETKA) into clean groove of retaining frame
-arrow-. Apply sealant evenly to sealing surface.
Note
♦ Sealant must not be applied too thickly. If necessary wipe

away excess sealant with a lint-free cloth.
♦ The retaining frame should be positioned and bolted on with‐
out interruption because the sealant begins to harden imme‐
diately when the sealing surfaces come into contact with each
other.
– Install the rear cap flush.

– Put on retaining frame and lightly tighten nuts of bearings 2
and 4 alternately and diagonally. Then lightly tighten nuts of
bearings 3, 1 and 5 likewise.
– Finally, tightenswnuts
agen in sequence shown.
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– Install cylinder
ed
by head cover. Tighten bolts diagonally
ua
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ris outside
sidethoto tee
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– Install
ss rear part of toothed-belt guard. c
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ab
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– Set seal in place using guide sleeve - T10071/1- and press in

atio
m
to stop using fitting sleeve - 3265- and bolt - T10071/2- .

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♦ Put a large, commercially available M12 washer under bolt to
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prevent wear on fitting sleeve.
ht. rig
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py by
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Prote AG.
– Insert Woodruff key in camshaft.
3. Valve gear 63
Caddy 2011 ➤
– Install camshaft pulley. When tightening camshaft toothed belt

pulley bolt, hold with counterhold - 3415- .
Install toothed belt ⇒ page 50 .
Note
After installing retaining frame and cylinder head cover, let sealing
compound dry for approx. 30 minutes.
Specified torques
♦ ⇒ “3.1 Assembly overview - valve gear”, page 56
3.4 Measuring axial play of camshaft

♦ Universal dial gauge bracket - VW 387-
♦ Dial gauge
Take measurements with retaining frame removed.
Wear limit: max. 0.17 mm
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3.5 Removing and installing valve stem seals ss a ra
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Prote AG.

Caddy 2011 ➤

equipment required
1331-
♦ Valve lever - VW 541/1 A-
with press tool - VW 541/6-
♦ Valve stem seal fitting tool -
3365-
♦ Pressure hose - VW 653/3-
♦ Valve assembly device -
2036-
♦ Valve stem seal puller -
3364-
AG. Volkswagen AG d
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Prote AG.
3. Valve gear 65
Caddy 2011 ➤
♦ Spark plug socket and extension - 3122 B-

♦ Puller - T10112-
Removing
– Remove camshaft ⇒ page 60 .
– Remove roller rocker finger. Place on a clean surface.
– When doing this, ensure that roller rocker fingers are not in‐
terchanged.
– Pull off spark plug connector using puller - T10112- .
– Unscrew spark plugs with spark plug spanner - 3122 B- .
– Set piston of respective cylinder to “bottom dead centre”.
– Fit valve assembly tool - 2036- and adjust mountings to height

of studs.
– Screw pressure hose - VW 653/3- into spark plug thread. AG. Volkswagen AG d
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– Connect pressure hose to air pressure source of at sleast
ed b 6 bar. ara
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– Remove valve springs using valve lever - VW a541/1
ut A- and ra
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press tool - VW 541/6- . ss
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Note
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Tight valve cotters can be loosened by tapping lightly on assem‐
, is n
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bly lever.
hole
spec
es, in part or in w
– Pull out valve stem seals using valve stem seal puller - 3364- .
t to the co
Installing
rrectness of i
– Place the plastic sleeve -A- supplied on the associated valve
l purpos
stem. This will prevent damage to the new valve stem seal.
– Insert new valve stem seal -B- in valve stem seal fitting tool -
nform
ercia
3365- .
m
a
– Oil valve stem seal sealing lip and press carefully onto the
com
tio
valve guide.
n in
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thi
Specified torques
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fo
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ng
t.
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♦ ⇒ “3.1 Assembly overview - valve gear”, page 56
Co
Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.
3.6 Checking hydraulic compensation ele‐
ments
♦ Feeler gauges
Test procedure
Note
♦ It is not possible to repair the supporting elements with hy‐

draulic clearance compensation.
♦ Irregular valve noise during starting is normal.

Caddy 2011 ➤
– Start engine and run until radiator fan has switched on once.
– Increase engine speed to about 2500 rpm for 2 minutes (per‐
form road test if necessary).
If the support elements with hydraulic clearance compensation
are still noisy, determine the defective support element as follows:
– Turn crankshaft until cams of supporting element to be tested
are at top.
– Press the roller rocker fingers downwards with a screwdriver
-arrow-.
If it is possible to insert a feeler gauge of 0.20 mm between cam‐
shaft and roller rocker finger:
– Renewing supporting element; removing camshaft to do so
⇒ page 60 .
Note
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♦ After installing camshaft, wait for approx. 30 minutesbybefore
Volk not
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starting engine. The hydraulic compensation elements rised must ara
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settle (otherwise valves will strike pistons). ut ho eo
ra
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♦ After working on the valve gear, turn the engine carefully at
s
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e
least 2 rotations to ensure that none of the valves make con‐

nl
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an
tact when the starter is operated.
itte
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erm
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ility
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es, in part or in w
t to the co
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mercia
at
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ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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t. rig
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Prote AG.
3. Valve gear 67
Caddy 2011 ➤
4 Inlet and exhaust valves

⇒ “4.1 Reworking valve seats”, page 68
⇒ “4.2 Checking valve guides”, page 69
⇒ “4.3 Valve dimensions”, page 70
4.1 Reworking valve seats

♦ Depth gauge
♦ Valve seat refacing tool
Note
♦ When repairing engines with leaking valves, it is not sufficient

to rework or renew valve seats and valves. There is also a
requirement to check the valve guides for wear. This is par‐
ticularly important on high mileage engines.
♦ Valve seats are only to be reworked to the extent required to
yield a proper surface appearance. Before beginning to rework
valve seats, calculate the maximum permissible reworking di‐
mensions. If the reworking dimension is exceeded, the hy‐
draulic valve clearance compensation can no longer be
guaranteed and the cylinder head must be renewed.
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gen AG does
The max. permissible reworking dimension is calculated as fol‐ Volkswa not
lows: ed
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ara
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– Insert valve and press firmly against seat. utho eo
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Note
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itte
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ab
ility
If the valve is to be renewed as part of a repair, use a new valve
ot p
for the calculation.
wit
, is n
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hole
spec
– Measure distance -a- between end of valve stem and upper
es, in part or in w
edge of cylinder head.
t to the co
– Calculate maximum permissible reworking dimension from
measured distance -a- and minimum dimension.
rrectness of i
Minimum dimension:
l purpos
Inlet valve 31.7 mm

nf
ercia
Exhaust valve 31.7 mm

orm
m
Measured distance -a- minus minimum dimension = maximum

atio
m
permissible reworking dimension.

o
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or c
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Example:
t
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cu
Measured distance -a- 32.0 mm

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- Minimum dimension 31.7 mm
yi Co
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t.
= max. perm. rework dimension 2) 0.3 mm
rig
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by
2) The max. permissible reworking dimension is shown as dimension “b” in the Prote
cted agen
illustrations for reworking valve seats.
AG.

Caddy 2011 ➤
Reworking inlet valve seat

Di‐ Inlet valve seat
men‐
sion
Diam‐ mm 39.2
eter a
b mm Max. permissible reworking dimension
c mm 1.8 … 2.2
Z Lower edge of cylinder head
45° Valve seat angle
30° Upper correction angle
Reworking exhaust valve seat

Di‐ Exhaust valve seat
men‐
sion
Diam‐ mm 32.4
eter a agen
AG. Volkswagen AG d
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Diam‐ mm Max. permissible reworking
by Vo dimension gu
ara
eter b orise
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c mm s a 2.2 … 2.6
u ra
c
s
Z Lower edge of cylinder head
ce
e
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45° Valve seat angle
itte
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erm
ab
30° Upper correction angle
ility
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4.2 Checking valve guides
hole
spec
es, in part or in w
t to the co
♦ Universal dial gauge bracket - VW 387-
rrectness of i
l purpos
nf
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orm
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atio
om
n in
or c
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Cop py
♦ Dial gauge
t. rig
gh ht
pyri by
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by
cted agen
Prote AG.
4. Inlet and exhaust valves 69

Caddy 2011 ➤
Test procedure
– Insert new valve in guide. Valve stem end must be flush with
guide. Since the stem diameters differ, only use inlet valve in
inlet guide and exhaust valve in exhaust guide.
– Determine rock tolerance, wear limit: 0.6 mm.
AG. Volkswagen AG d
If rock tolerance is exceeded: agen oes
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– Renew cylinder head. rised
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4.3 Valve dimensions
is n
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spec
t to the co
Note
Valves must not be reworked. Only lapping-in is permitted.
rrectne
Dimension Inlet valve Exhaust valve
ss o
Diameter a mm 39.5 ± 0.15 32.9 ± 0.15
cial p
f inform
Diameter b mm 5.98 ± 0.007 5.965 ± 0.007
mer
atio
c mm 93.85 93.85
om
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i
α ∠° 45 45
or
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by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump and oil pump”, page 71
⇒ “1.2 Removing and installing oil sump”, page 73
⇒ “1.3 Removing and installing oil pump”, page 75
⇒ “1.4 Engine oil”, page 76
1.1 Assembly overview - sump and oil pump
Note AG. Volkswagen AG d

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♦ Finding metal shavings or a large quantity oforissmall metal particles during engine repair
e ntecould indicate that
eo
the crankshaft bearings or conrod bearings
aut are damaged. To prevent this from causing further
h
ra damage,
perform the following repairs: ss c
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pt
♦ Thoroughly clean oil channels.
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erm
♦ Renew oil filter.
ab
ility
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♦ Renew oil spray jets (if fitted).
wit
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ole,
♦ Renew engine oil cooler.
spec
♦ The oil level must not be above the max. mark - danger of damage to catalytic converter!
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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Prote AG.
1. Sump, oil pump 71

Caddy 2011 ➤
1 - Bolt
❑ 15 Nm
2 - Bracket
❑ For oil level and oil tem‐
perature sender - G266-
wiring harness.
3 - Dipstick
❑ The oil level must not be
above the max. mark!
❑ Markings ⇒ page 76 .
4 - Piston fitting tool
❑ Pull out to extract oil.
5 - Guide tube
6 - Dowel sleeves
7 - O-ring
8 - Bolt
❑ 15 Nm
9 - Suction line
❑ Clean strainer if soiled.
10 - Baffle plate
11 - Bolt
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12 - Bolt ised b ara
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❑ 15 Nm aut
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13 - Oil sump
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❑ Clean sealing surface pt

an
d
itte
before fitting. y li
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ab
ility
❑ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
ot p
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is n

h re
ole,
spec
14 - Seal
❑ Rolled onto oil drain plug.

t to the co
15 - Oil drain plug

rrectne
❑ with captive seal

s
❑ 30 Nm
s o
cial p
f in
16 - Bolt
form
mer
❑ 10 Nm
atio
om
17 - Oil level and oil temperature sender - G266-

c
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❑ Checking ⇒ Vehicle diagnostic tester

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18 - Seal
um
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fo
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ng

t.
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. rig
19 - Oil pump
ht ht
rig by
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❑ With 12 bar pressure relief valve by c lksw
cted agen
Prote AG.
❑ Before installing, check that both dowel sleeves for centring the oil pump on the cylinder block are fitted.
❑ Renew if running surfaces and gears are scored.
72 Rep. gr.17 - Lubrication

Caddy 2011 ➤
20 - Chain sprocket
21 - Bolt
❑ 20 Nm + 90°
22 - Chain
23 - Sealing flange
❑ Silicone sealant ⇒ Electronic Parts Catalogue (ETKA)
❑ Renewing crankshaft seal on poly V-belt pulley end ⇒ page 21 .
24 - Chain tensioner with tensioning rail
❑ When installing, pretension spring and fit.
❑ 15 Nm
1.2 Removing and installing oil sump

equipment required
♦ Jointed wrench 10 mm AF -
3185-
♦ Allen key, long reach - AG. Volkswagen AG d
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♦ Torque wrench - V.A.G orise nte
1331- aut
h eo
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ss c
♦ Silicone sealant ⇒ Elec‐
ce
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nl
pt
tronic Parts Catalogue (ET‐
du
an
itte
KA)
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erm
ab
ility
♦ Eye protection
ot p
wit
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♦ Flat scraper
h re
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spec
♦ Hand drill with plastic brush
es, in part or in w
t to the co
rrectness of i
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Cop py
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rig ht
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by lksw
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Prote AG.
Removing

Caddy 2011 ➤
– Drain off engine oil.
Note
Observe environmental regulations for disposal.
– Unscrew gearbox/sump securing bolts.

– Pull 3-pin connector off oil level and oil temperature sender -
G266- .
– Loosen or tighten sump bolts using 10 mm jointed wrench -
3185- . Loosen and tighten only flywheel-end bolts using Allen
key, long reach - T10058- .
– Remove sump. Loosen sump with light blows using a rubber
headed hammer if necessary.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove sealant residues on sump with a rotating brush, e.g.
an electric drill with plastic brush attachment (wear eye pro‐
tection).
Installing
Note

♦ The sump must be installed within 5 minutes of applying sili‐ agen
AG. Volkswagen AG d
oes
cone sealing compound. Volksw not
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ut ra
– Cut off nozzle on tube at front marking (diameter of nozzle:
ss a c
approx. 3 mm).
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an
– Apply silicone sealant to clean sealing surface of sump as
itte
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erm
shown. Sealant bead must be:
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ility
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♦ 2…3 mm thick.
wit
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♦ run along inside of bolt holes -arrows-.
hole
spec
es, in part or in w
Note t to the co
rrectness of i
The sealant bead must not be thicker, otherwise excess sealing

compound will enter the oil sump and may block the oil suction
l purpos
line strainer.
nf
ercia
orm
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Prote AG.

Caddy 2011 ➤
– Sealant bead must be applied with extreme care in vicinity of

arrows.
– Position oil sump immediately and tighten bolts as follows:
1 - Tighten all sump/cylinder block bolts only very lightly and di‐
agonally.
2 - Tighten sump/gearbox bolts lightly.
3 - Further tighten all sump/cylinder
agen
AG.block
Volkswbolts
agen Alightly
G do using di‐
agonal sequence. Volksw es n
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by ua
ed ran
4 - Tighten bolts between
ho
ris sump and gearbox. tee
t or
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5 - Tighten diagonally
ss all bolts between sump and cylinder block.
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Note
erm
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♦ When installing sump with engine out of the vehicle, ensure
wit
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that sump is flush with cylinder block at flywheel end.
h re
hole
spec
♦ Let sealing compound dry for approx. 30 minutes after instal‐
es, in part or in w
ling oil sump. Only then fill with engine oil.
t to the co
Specified torques
rrectness of i
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nf
ercia
Component Specified torque orm

m
atio
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Sump/gearbox 25 Nm
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thi
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1.3 Removing and installing oil pump

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Removing
t.
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Cop py
t. rig
– Remove sump and oil-sump baffle plate ⇒ page 73 . opyri
gh by
Vo
ht
c lksw
– Remove bolt -2-.
by
cted agen
Prote AG.
– Remove chain sprocket from the oil-pump shaft.

– Remove bolts -1- and -5- and remove oil pump.
Installing
– Insert top dowel sleeves ⇒ Item 6 (page 72) on the oil pump.
The chain sprocket can only be fitted in one position on the oil
pump shaft.
– Install sump ⇒ page 73 .
Specified torques
Sump/gearbox 25 Nm

Caddy 2011 ➤
4-cylinder injection n AG. Volk(1.6
ageengine
swagen AG
l engine,
does BiFuel) - Edition 12.2015
lksw o n ot g
yV ua
edb ran
1.4 Engine oil
tho
ris tee
or
au ac
ss
Oil capacities:
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pt
du
With oil filter 4.5 l
an
itte
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Engine oil specifications
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⇒ Maintenance ; Booklet 39
, is n
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hole
spec
es, in part or in w
Note
t to the co
♦ The engine is filled with oil at the factory and this oil is designed
for long service intervals.
rrectness of i
♦ Engine oils conforming to VW standard 501 01 or 502 00 can
l purpos
continue to be used. These oils must be changed every 12

months or 15,000 kilometres. The service interval display must
nf
ercia
be programmed accordingly ⇒ Maintenance ; Booklet 39 .
orm
m
atio
m
Markings on oil dipstick

o
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Old version:
thi
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1 - Max. mark
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2 - Min. mark
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Cop py
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a - Oil level in max. mark area: Do not top up with engine oil!
rig
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pyri by
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b - Oil level in middle range: Can be topped up with engine oil.
lksw
cted agen
Prote AG.
c - Oil level in min. mark area: Replenish with approx. 0.5 l engine
oil!
New version:
1 - Max. mark
2 - Min. mark
a - Oil level in max. mark area: Do not top up with engine oil!
b - Oil level in middle range: Can be topped up with engine oil.
c - Oil level in min. mark area: Replenish with approx. 0.5 l engine
oil!

Caddy 2011 ➤
2 Oil filter, oil pressure switch

⇒ “2.1 Assembly overview - oil filter/oil pressure switch”,
page 77
⇒ “2.2 Checking oil pressure and oil pressure switch”,
page 78 AG. Volkswagen AG d
agen oes
⇒ “2.3 Measure oil consumption”, page 79 olksw not
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2.1 Assembly overview - oil filter/oil pressure switch author eo
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1 - Plug
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❑ 15 Nm
erm
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ility
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2 - Seal
wit
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❑ If seal is leaking, nip
hole
open and renew.
spec
es, in part or in w
3 - Oil pressure switch - F1-
t to the co
❑ Black
❑ 1.4 bar
rrectness of i
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❑ 25 Nm
4 - Seal
nf
ercia
or
❑ If seal is leaking, nip
m
m
atio
open and renew.
om
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or c
5 - Oil filter bracket
thi
te
sd
a
❑ With pressed-in non-re‐

iv
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turn valve.
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6 - Bolt
Co
Cop py
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❑ Renew after removing opyri
gh by
Vo
ht
❑ 15 Nm + 90°
c by lksw
cted agen
Prote AG.
7 - Oil filter
❑ Loosen with strap
wrench or oil filter tool -
3417- .
❑ Tighten by hand.
❑ Observe installation in‐
structions on oil filter.
8 - Plug
❑ 40 Nm
9 - Seal
❑ Permanently attached to ⇒ Item 8 (page 77) .
10 - Spring
❑ For pressure relief valve, approx. 4 bar.
11 - Piston
❑ For pressure relief valve, approx. 4 bar.
12 - Gasket
13 - Oil non-return valve
❑ Pressed into oil filter bracket.
2. Oil filter, oil pressure switch 77

Caddy 2011 ➤
❑ No replacement part
wagavailable
en AG. V
olkswagen AG
does
ks not
Vol gu
14 - O-ring ed by ara
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utho eo
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2.2
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Checking oil pressure and oil pressure

un
pt
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d
switch
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pe
ility
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♦ Oil pressure tester - V.A.G 1342-
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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com
tion in
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♦ Auxiliary measuring set - V.A.G 1594 C-

do
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fo
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t.
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Cop py
t. rig
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pyri by
Vo
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Prote AG.
♦ Voltage tester - VAS 6839-
Test specifications:
• Engine oil level OK.
• Engine oil temperature at least 80 °C (radiator fan must have
run once)
Note
Functional check and repair of the optical and acoustic oil pres‐
sure gauge: current flow diagrams ⇒ Vehicle diagnostic tester

Caddy 2011 ➤
Test sequence:
– Remove oil pressure switch - F1- and screw it into oil pressure
tester - V.A.G 1342- .
– Screw oil pressure tester - V.A.G 1342- into oil filter bracket in
place of the oil pressure switch.
– Connect brown wire of tester to earth (-).
– Connect voltage tester - VAS 6839- to battery positive (+) and
oil pressure switch using cables from auxiliary measuring set
- V.A.G 1594 C- . LED must not light up.
. Volkswagen AG
gen AG does
– If the LED lights up, renew the 1.4 bar oil pressure switch V-olkswa not
gu
F1- . ed
by ara
nte
ris
If LED does not light up: utho eo
ra
a c
ss
– Start engine and increase rpm; at pressure of 1.2…1.6 bar,
ce
e
nl
pt
LED must light up. Otherwise renew oil pressure switch.
du
an
itte
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erm
– Increase engine speed further. At 2000 rpm and oil tempera‐
ab
ility
ture of 80°C, oil pressure should be between 2.7 and 4.5 bar.
ot p
wit
, is n
At higher engine speeds, the oil pressure must not exceed 7.0
h re
hole
bar.
spec
es, in part or in w
If specification is not attained:
t to the co
– Then check suction line strainer for dirt ⇒ Item 9 (page 72) .
rrectness of i
Note
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Mechanical damage, e.g. to the bearings, could also be the cause
nform
ercia
of the oil pressure being too low.

m
at
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io
If no fault is found:
n
c
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– Renew oil pump ⇒ page 75 .

at
do
priv
c
If the specification is exceeded:
um
for
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ng
t.
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– Check oil channels.
Co
Cop py
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gh
– If necessary, renew oil filter bracket with pressure relief valve.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2.3 Measure oil consumption
♦ Vehicle diagnostic tester
Procedure
– Pull handbrake on.
– Manual gearbox: gear stick in neutral.
– Automatic gearbox: move selector lever to position “N”.
– Switch ignition on.
– Carry out program Oil consumption measurement using
⇒ Vehicle diagnostic tester and follow instructions.
2. Oil filter, oil pressure switch 79

Caddy 2011 ➤
19 – Cooling
1 Cooling system, coolant
⇒ “1.1 Coolant hose schematic diagram”, page
gen AG
. Vo80
lkswagen AG
a does
lksw not
⇒ “1.2 Draining and filling coolant”,
db
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o gu
ara
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⇒ “1.3 Checking cooling system
ut
ho for leaks”, page 85 eo
ra
a c
ss
1.1 Coolant hose schematic diagram
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le
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1 - Radiator/cooler
pe
ility
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wit
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⇒ page 95 .
h re
hole
spec
❑ After replacement, refill
es, in part or in w
system with fresh cool‐
t to the co
ant
2 - Thermostat
rrectness of i
thermostat
l purpos
⇒ page 91 .
❑ Checking:
nform
ercia
⇒ Item 19 (page 88) .

m
a
3 - Coolant pump
com
tion in
r
te o
thi
s
iva
do
coolant pump
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rp
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⇒ page 89 .
fo
en
ng
t.
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4 - Cylinder head/cylinder Cop py
. rig
block
ht ht
rig by
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❑ After replacement, refill by c lksw
cted agen
system with fresh cool‐ Prote AG.
ant
5 - Coolant expansion tank
❑ With cap
❑ Checking pressure re‐
lief valve in filler cap
⇒ page 85 .
6 - Intake manifold with heated
throttle valve housing
7 - Vaporiser
8 - Heat exchanger for heater
❑ After replacement, refill
system with fresh cool‐
ant
9 - Engine oil cooler
80 Rep. gr.19 - Cooling

Caddy 2011 ➤
1.2 Draining and filling coolant

equipment required
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist
- VAS 6208-
6340-
♦ Cooling system charge unit
- VAS 6096- n AG. Volkswagen A ge G do
swa es n
♦ Adapter for cooling by
Vsystem
olk ot g
ua
tester - V.A.G r1274/8-
ised ran
tee
tho or
s au ac
s
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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
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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
Draining
co Vo
by lksw
cted agen
Prote AG.
Note
♦ Collect drained coolant in a clean container for re-use or dis‐

posal.
♦ Observe waste disposal regulations.
Caution
WARNING

scalding. Cover cap with cloth and open carefully.
1. Cooling system, coolant 81

Caddy 2011 ➤
– Open filler cap on coolant expansion tank.

– Open drain plug -arrow- on radiator. If necessary fit drain hose
to connection.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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nl
pt
du
Note
an
itte
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erm
ab
Vehicles without drain plug: pull out retaining clip -arrow- and pull
ility
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coolant hose off radiator.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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– Also remove bottom coolant hose from engine oil cooler

-arrow- and drain remaining coolant.
nform
ercia
Filling
m
at
om
ion
c
in t
or
his
ate
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.

Caddy 2011 ➤
Note
♦ Only distilled water may be used for mixing with coolant addi‐
tives. Using distilled water ensures optimum protection against
corrosion.
♦ The amount of water used in the coolant mixture has a great
influence on its effectiveness. 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 satisfies all requirements. For this reason, we recom‐
mend using distilled water when mixing coolant for topping up
or replacing 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 engine.
♦ The correct coolant solution ratio helps prevent damage from
freezing and corrosion as well as scaling. Moreover, the boil‐
ing temperature is raised. Therefore, the cooling system must
be filled all year round with coolant additive.
♦ Because of its higher boiling point, the coolant improves en‐
gine reliability under heavy loads, particularly in countries with
tropical climates.
♦ The refractometer - T10007A- must be used to determine the
current anti-freeze value.
♦ Frost protection must be guaranteed down to -25°C as a nmin‐
wage
AG. Volkswagen AG d
oe
imum and, in countries with arctic conditions, down y V to approx.
olks s no
t gu
-36°C. Increasing the frost protection is permissible
edb only if cli‐ ara
nte
ris
matic conditions require stronger frost protection.
tho It may, how‐ eo
ever, only be increased to a maximumssof au -48°C. Otherwise, ra
c
the cooling effect of the coolant will be impaired.
ce
le
un
pt
an
d
♦ The coolant concentration must not be reduced by adding wa‐

itte
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ter even in warmer seasons and in warmer countries. Frost
rm
ab
pe
protection must be guaranteed down to at least -25°C.

ility
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wit
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♦ Read the frost protection value from the respective scale for h re
the coolant additive being used.
hole
spec
es, in part or in w
♦ The temperature read off the refractometer - T10007A- equa‐

t to the co
tes to the »ice flocculation point«. Flakes of ice may start

forming in the coolant below this temperature.
rrectness of i
♦ Do not reuse old coolant.

l purpos
♦ Use only a water/coolant additive mixture as a slip agent for

coolant hoses.
nform
ercia
Recommended mixture ratios:

m
a
com
tio
Frost protection Coolant additive Coolant ad‐ Distilled wa‐

n in
r
down to portion ditive 3) ter3)

te o
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-25°C 40 % 3.2 l 4.8 l

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-36°C 50 % 4.0 l 4.0 l

fo
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3) The quantity of coolant can vary depending upon vehicle equipment. C py
ht. rig
rig ht
py by
co Vo
by lksw
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Prote AG.

Caddy 2011 ➤
– Close drain plug -arrows-.

– Re-attach coolant hoses and secure with clips.
– Install noise insulation ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body - front; Noise insulation .
– Fill tank of cooling system charge unit - VAS 6096- with at least
8 litres of pre-mixed coolant in correct mixture ratio:
– Screw adapter for cooling system tester - V.A.G 1274/8- onto
coolant expansion tank -1-.
– Mount cooling system charge unit - VAS 6096- on adapter -
V.A.G 1274/8- .
– Feed vent hose -2- into a small container -3-.
Note
Exhaust air takes a slight quantity of coolant along with it; this
should be collected.
– Close valves -A- and -B- (turn lever transverse to direction of

flow to do this).
– Connect hose -4- to compressed air.
• Pressure: 6 … 10 bar.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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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
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
84
cted agen
Prote AG.
Rep. gr.19 - Cooling
Caddy 2011 ➤
– 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 hose of coolant expansion tank 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 the gauge must remain in
the 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.
olkswagen AG
en AG. V
♦ If vacuum drops, cooling system must be checked for leaks.
olks
wag does
not
yV gu
db ara
ir se nte
– Pull off compressed air hose. ut
ho eo
a ra
ss c
– Open valve -A-.
ce
le
un
pt
• The vacuum in the cooling system causes coolant to be ex‐
an
d
itte
y li
tracted from coolant expansion tank of cooling system charge
rm
ab
unit - VAS 6096- and the cooling system to be filled.
pe
ility
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wit
, is n
– Then install cooling system charge unit - VAS 6096- again on
h re
coolant expansion tank.
hole
spec
es, in part or in w
– Fill coolant up to max. mark.
t to the co
Without cooling system charge unit - VAS 6096- :
rrectness of i
– Slowly fill coolant in up to upper marking of hatched field on
expansion tank.
l purpos
– Fit expansion tank cap.

nform
ercia
– Start engine and keep engine speed at approx. 2000 rpm for
about 3 minutes.
m
a
com
tio
– Run engine until fan cuts in.

n in
r
te o
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s
iva
do
WARNING
r
rp
cum
fo
en
ng
t.
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Co
op py
t. C rig
gh ht
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scalding. Cover cap with cloth and open carefully. p by
co Vo
by lksw
cted agen
Prote AG.
– Check coolant level and top-up if necessary. When the engine

is at normal operating temperature, the coolant level must be
at the upper mark; when the engine is cold, in the middle of
the hatched field.
1.3 Checking cooling system for leaks

Caddy 2011 ➤
AG. Volkswagen AG d
Special tools and workshop ksw
agen oes
not
l
equipment required by Vo gu
ara
d
ise nte
♦ Cooling system tester - uthor eo
V.A.G 1274 B- ss a ra
c
ce
e
♦ Adapter for cooling system
nl
pt
du
an
tester - V.A.G 1274/8-
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
nform
mercia
at
om
ion
c
in t
or
his
ate
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.
Test prerequisite
• Engine at operating temperature
Test sequence:
WARNING
Hot steam/coolant can escape - risk of scalding!

The cooling system is under pressure when the engine is hot.
Cover filler cap on expansion tank with a cloth and open care‐
fully to dissipate pressure.
– Open filler cap on coolant expansion tank.

– Screw adapter for cooling system tester - V.A.G 1274/8- into
coolant expansion tank.
– Clamp connector - V.A.G 1274 B/1- into adapter for cooling
system tester - V.A.G 1274/8- .

Caddy 2011 ➤
– Join connection piece - V.A.G 1274 B/1- to cooling system

tester - V.A.G 1274 B- using connecting hose supplied.
– Using hand pump on tester, build up a pressure of approx. 1.0
bar.
DANGER!
Risk of scalding! Before disconnecting cooling system tester -

V.A.G 1274 B- from connecting hose or connector - V.A.G
1274 B/1- , always relieve existing pressure. To do this, press
pressure relief valve on cooling system tester - V.A.G 1274 B-
until pressure gauge displays value of »0«.
If pressure drops:
– Find leaks and eliminate them. AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
s c
Checking pressure relief valve in filler cap: s
ce
e
nl
pt
du
– Screw cap -1- into adapter for cooling system tester - V.A.G
an
itte
y li
1274/9- .
erm
ab
ility
ot p
– Connect cooling system tester - V.A.G 1274 B- using adapter
wit
, is n
for cooling system tester - V.A.G 1274/9- .
h re
hole
spec
– Build up pressure using hand pump of cooling system tester.
es, in part or in w
t to the co
• The pressure relief valve should open at a pressure of 1.4…
1.6 bar.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
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for
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Cop py
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Vo
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cted agen
Prote AG.

Caddy 2011 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 88
⇒ “2.2 Removing and installing the coolant pump”, page 89
⇒ “2.3 Removing and installing the thermostat”, page 91
2.1 Assembly overview - coolant pump, thermostat
1 - Throttle valve module -

J338-
2 - Seal
3 - To heat exchanger for heat‐
er
4 - Coolant distributor housing
5 - O-ring
6 - Coolant temperature send‐
er - G62-
7 - Retaining clip
8 - To top of radiator
9 - Bolt
❑ 10 Nm
10 - Coolant pipe AG. Volkswagen AG d
agen oes
lksw not
11 - Bolt by
Vo gu
ara
ed
❑ 40 Nm horis nte
eo
aut ra
12 - Hose to expansion tank ss c
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nl
pt
13 - O-ring
du
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itte
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erm
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ility
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14 - To coolant hose at top of

wit
, is n
radiator
h re
hole
spec
15 - Hose to bottom of radiator

es, in part or in w
t to the co
16 - Bolt
❑ 15 Nm
rrectness of i
17 - Connection
l purpos
18 - O-ring
nf
ercia
19 - Thermostat
orm
m
atio
❑ Checking: heat thermostat in water.

om
n in
c
❑ Opening begins at approx. 87 °C.

or
thi
e
❑ Fully open: at approx. 102 °C.

t
sd
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❑ Opening lift: min. 7 mm

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Prote AG.

Caddy 2011 ➤
20 - Engine oil cooler

21 - O-ring
22 - Coolant pump
23 - O-ring
24 - Breather pipe
25 - Bolt
❑ 10 Nm
26 - Bolt
❑ 10 Nm
2.2 Removing and installing the coolant

pump
♦ Drip tray for workshop hoist - VAS 6208-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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or eo
h
aut ra
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nl
pt
du
♦ Spring-type clip pliers - VAS 5024A- 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
nform
ercia
Removing
m
at
om
ion
c
in t
WARNING
or
his
ate
do
riv

p
cum
or

f
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t.
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Cop py
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– Drain coolant ⇒ page 81 . Prote
cted AG.
agen
2. Coolant pump, regulation of cooling system 89

Caddy 2011 ➤
– Remove deflector plate -2-.

– Remove tensioning element -1-for poly V-belt.
– Removing upper part of toothed belt guard ⇒ page 49 .
– Release tooth-belt tensioning roller and remove toothed belt
from camshaft pulley.
– Remove the centre toothed-belt guard -arrows-.
Note
♦ The poly V-belt pulley and lower toothed-belt guard can re‐
main installed.
♦ The toothed belt stays on the crankshaft toothed-belt pulley.
♦ Before removing coolant pump, cover toothed belt with a cloth
to protect it from coolant.
lkswage es n
o ot g
byV ua
d ran
ir se tee
– Unscrew securing bolts -1- of coolant pump and remove
utho cool‐ or
ant pump -2-. ss
a ac
ce
e
– Remove O-ring -3-.

nl
pt
du
an
itte
Installing y li
erm
ab
ility
ot p
Installation is carried out in the reverse order; note the following: wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Renew O-ring.
rrectness of i
– Clean and smooth sealing surface for O-ring.

l purpos
nf
ercia
orm
m
atio
om
n in
or c
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sd
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cted agen
Prote AG.

Caddy 2011 ➤
– Coat new O-ring -3- with coolant.

– Insert coolant pump -2-.
• Installation position: plug in the housing faces downwards.
– Tighten coolant pump bolts -1-.
– Install toothed belt (adjust valve timing) ⇒ page 50 .
Specified torques
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 88
2.3 Removing and installing the thermostat

equipment required
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist
- VAS 6208-
6340-
AG. Volkswagen AG d
♦ Cooling system charge unit agen oes
olksw not
- VAS 6096- ed by
V gu
ara
ris nte
♦ Adapter for cooling system aut
ho eo
ra
tester - V.A.G 1274/8- ss c
ce
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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
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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Cop py
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Prote AG.
2. Coolant pump, regulation of cooling system 91

Caddy 2011 ➤
♦ Jointed wrench 10 mm AF - 3185-

♦ 5 mm AF long-reach Allen key - 3249-
Removing
WARNING

– Drain coolant ⇒ page 81 .

– Pull coolant hose off connection.
– Undo securing bolts -4- using Jointed ewrench . Volk10

swamm
gen AAF
G do-
g n AG
3185- and unscrew with 5 mm AF olklong-reach
swa Allen key - 3249-es n
ot g
and remove connection -3-.ed by V ua
ra
is nte
or
– Pull thermostat out of acylinder
ut
h block using pliers. eo
ra
ss c
Installing
ce
le
un
pt
an
d

itte
y li
erm
ab
– Moisten the new O-ring with coolant.

ility
ot p
wit
is n
– Insert thermostat -1- with O-ring -2- into the cylinder block.
h re
ole,
spec
Note
t to the co
The brace on the thermostat must be almost vertical.

rrectne
– Fit connection -3- and tighten securing bolts -4- using Jointed
wrench 10 mm - 3185- .
ss o
cial p
– Connect coolant hose to connection and top up with coolant

inform
⇒ page 81 .
mer
atio
m
Specified torques
o
n
c
i
or
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,

thi
te
sd
a
page 88
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t.
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Cop py
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co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator and radiator fan”,
page 93
⇒ “3.2 Removing and installing radiator”, page 95
⇒ “3.3 Removing and installing radiator fan V7 and radiator fan 2
V177 ”, page 96
AG. Volkswagen AG d
agen
3.1 Assembly overview b-y Vradiator and radi‐
w oes
olks not
gu
ara
ator fan ed
ris nte
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au ra
c
ss
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le
Note
un
pt
an
d
itte
y li
rm
ab
Vehicles are also fitted with one radiator fan only, depending on
pe
ility
vehicle equipment. The same procedure is used for removal and
ot
wit
, is n
installation as that which is used for the dual fan described below.
h re
hole
spec
es, in part or in w
t to the co
1 - Upper coolant hose
❑ To connection on cylin‐
der head.
rrectness of i
2 - O-ring
l purpos
❑ Renew if damaged.
3 - Radiator/cooler
nform
ercia
❑ After renewing, renew

m
a
com
t
entire coolant.
ion in
r

te o
thi
⇒ page 95 .
s
iva
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rp
cum
4 - Gasket
fo
en
ng
t.
yi Co
5 - Cap t. Cop py
rig
❑ Check using cooling
gh ht
pyri by
system tester - V.A.G
o Vo
by c lksw
cted
1274- and adapter for
agen
Prote AG.
cooling system tester -
V.A.G 1274/9- .
❑ Pressure relief valve
should open at between
1.4 and 1.6 bar
6 - Connector
7 - Bolt
❑ 5 Nm
8 - Coolant expansion tank
❑ Test cooling system for
leaks using cooling sys‐
tem tester - V.A.G 1274-
and adapter for cooling
system tester - V.A.G
1274/8- .
9 - Radiator mounting
10 - Bolt
❑ 5 Nm
3. Radiator, radiator fan 93

Caddy 2011 ➤
11 - Support
12 - Nut
AG. Volkswagen AG d
❑ 10 Nm lksw
agen oes
not
o
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13 - Cowling rised b ara
nte
ho eo
14 - Bolt aut ra
ss c
❑ 5 Nm
ce
le
un
pt
an
d
15 - Radiator fan 2 - V177-

itte
y li
rm
ab
pe
ility
ot
wit
16 - Connector
, is n
h re
hole
17 - Radiator fan - V7-
spec
es, in part or in w
❑ With radiator fan control unit - J293- .
t to the co
18 - Lower coolant hose
rrectness of i
❑ To connection for thermostat.
l purpos
19 - Retaining clip
nform
ercia
20 - Radiator outlet coolant temperature sender - G83-

m
21 - O-ring
a
com
tion in
r
te o
thi
s
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fo
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t.
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.

Caddy 2011 ➤
3.2 Removing and installing radiator

equipment required
♦ Refractometer - T10007 A- AG. Volkswagen AG d
agen oes
lksw not
♦ Drip tray for workshop hoist by Vo gu
ara
- VAS 6208- rise
d
nte
tho eo
u
♦ Hose clip pliers - VAS ss a ra
c
6340-
ce
e
nl
pt
du
an
♦ Cooling system charge unit
itte
y li
- VAS 6096-
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
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
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t.
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Cop py
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Vo
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cted agen
Prote AG.
Removing
WARNING

– Drain coolant ⇒ page 81 .

– Remove front bumper ⇒ General body repairs, exterior; Rep.
gr. 63 ; Bumpers .
– Remove cowling ⇒ Item 13 (page 94) .
– Pull coolant hoses off radiator.

Caddy 2011 ➤
Caution
To prevent damage to condenser or to refrigerant lines/hoses,

ensure that the lines and hoses are not stretched, kinked or
bent.
– Unscrew bolts -1- on the radiator.

Vehicles with air conditioning system:
– Swing radiator backwards slightly.
– Undo and remove condenser bolts -2-.
Continuation for all vehicles:
– Remove radiator upwards.
Installing
– Install front bumper ⇒ General body repairs, exterior; Rep. gr.
63 ; Bumpers .
– Install cowling ⇒ Item 13 (page 94) . n AG. Volkswagen AG do
lkswage es n
o ot g
yV ua
– Replenish coolant ⇒ page 81 . ir se
d b ran
tee
tho
or
Specified torques au ac
ss
ce
le
♦ ⇒ “3.1 Assembly overview - radiator and radiator fan”,

un
pt
page 93
an
d
itte
y li
erm
ab
ility
3.3 Removing and installing radiator fan -
ot p
wit
is n
V7- and radiator fan 2 - V177-

h re
ole,
spec
Removing
t to the co
– Pull off the air guide hose for the damping chamber from the
lock carrier.
rrectne

ss
– Pull off bottom coolant hose -arrow- on the damping chamber

o
cial p
and remove it.

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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Disconnect the electrical connector -1- and unscrew lower se‐

curing bolts for the cowling -arrows-.
– Unscrew air duct on lock carrier -arrows-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Unscrew the top securing bolts for the cowling -arrow- and re‐
wit
is n
move the cowling upwards.
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
– Disconnect electrical connector -1- and free electrical wiring.

n
c
i
or
n thi
e
– Unscrew nuts -arrows- and remove fan.

t
sd
iva
o
pr
cum
Installing
r
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
Specified torques yri
p by
o Vo
by c lksw
cted
♦ ⇒ “3.1 Assembly overview - radiator and radiator fan”,
agen
Prote AG.
page 93

Caddy 2011 ➤
20 – Fuel supply system agen

AG. Volkswagen AG d
oes
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y V gu
1 Fuel tank d b ara
rise nte
tho eo
au ra
⇒ “1.1 Assembly overview - fuel tank”, page 98 ss c
ce
e
nl
⇒ “1.2 Removing and installing fuel tank”, page 99
pt
du
an
itte
y li
1.1 Assembly overview - fuel tank
erm
ab
ility
ot p
wit
, is n
h re
Caution
hole
spec
es, in part or in w
The fuel pump must not be allowed to run when the fuel tank
t to the co
is empty, as this may cause deflagrations.
The fuel tank must contain at least 5 litres of fuel.
rrectness of i
l purpos
1 - Cover flange
nf
ercia
or
2 - Cap
m
m
atio
m
❑ Renew seal if damaged.

o
n in
or c
3 - Securing bolt
thi
te
sd
iva
o
r
4 - Activated charcoal filter

rp
cu
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f
en
❑ Location: on fuel tank.
ng
t.
yi Co
op py
5 - Breather line t. C rig
gh ht
yri by
❑ To activated charcoal fil‐ cop Vo
by lksw
ter solenoid valve 1 - cted agen
Prote AG.
N80-
6 - Securing strap
❑ Note installation posi‐
tion.
7 - Bolt
❑ 25 Nm
8 - Breather connection
❑ Clipped onto breather
pipe
9 - Pressure retention valve
10 - Securing bolt
11 - Fuel filter
❑ Installation position: ar‐
row indicates direction
of flow.
❑ Fuel filter with attached
parts ⇒ page 105
⇒ page 106 .
12 - To engine
13 - Fuel tank
14 - Fuel delivery unit
❑ Clean strainer if dirty.
98 Rep. gr.20 - Fuel supply system

Caddy 2011 ➤
❑ With fuel gauge sender - G- .
❑ Removing and installing fuel gauge sender - G- ⇒ page 104 .
❑ Checking fuel pump ⇒ page 132 .
❑ Note installation position on fuel tank ⇒ page 104 .
15 - Seal
❑ Renew if damaged. lkswage es n
Vo ot g
❑ When installing, fit dry in fuel tank d opening.
by ua
ran
ir se tee
❑ Moisten with fuel only whenuthinstalling flange.
o
or
a ac
ss
16 - Locking ring
ce
e
nl
pt
du
an
itte
y li
❑ Remove and install using union nut tool - 3217- .
erm
ab
ility
ot p
❑ 80 Nm
wit
, is n
h re
17 - Supply line
hole
spec
❑ Black
es, in part or in w
t to the co
❑ Clipped onto fuel tank.
rrectness of i
18 - Return line
❑ Blue
l purpos
❑ Clipped onto fuel tank.

nform
mercia
at
om
ion
c
in t
1.2 Removing and installing fuel tank
or
his
ate
do
priv
cum
or
Caution
f
en
ng
t.
yi Co
op py
t. C rig
gh ht
yri
is empty, as this may cause deflagrations. p by
co Vo
by lksw
cted agen
The fuel tank must contain at least 5 litres of fuel. Prote AG.

♦ Torque wrench - V.A.G 1331-
1. Fuel tank 99
Caddy 2011 ➤
♦ Engine and gearbox jack - V.A.G 1383 A-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
Removing
h re
ole,
spec
– Note safety precautions before starting installation work
⇒ page 4 .
t to the co
Note
rrectne
♦ Vehicles with the Autogas system do not have a spare wheel
s
as the Autogas cylinder is located in the spare wheel well.
s o
cial p
f in
♦ Autogas cylinder does not need to be removed in order to re‐
form
mer
move the fuel tank.

atio
om
n
c
– Remove spare wheel (if fitted).

i
or
n thi
te
sd
a
– Unbolt left rear wheel.

iv
o
pr
cum
r
fo
– Remove rear left wheel housing liner ⇒ Rep. gr. 66 .

en
ng
t.
yi Co
op
– Remove cover flange ⇒ Item 1 (page 98) . C py
t. rig
gh ht
yri by
– Unbolt filler neck from body. cop Vo
by lksw
cted agen
Prote
– Disconnect breather line -arrow- (white) at activated charcoal
AG.
filter.
Note
Press in securing ring to release line.
WARNING
Fuel supply lines are under pressure! Wear eye protection and
protective clothing to avoid possible injury and skin contact.
Before loosening hose connections, wrap a cloth around the
joint. Then release the pressure by carefully pulling the hose
off the connection.

Caddy 2011 ➤
– Disconnect fuel supply line -arrow- (black) at fuel filter.

– Unscrew securing strap and securing bolts. When doing this,
support fuel tank with enginewand gearbox
gen AG. Volkswjack - V.A.G
agen AG
does 1383
s a
A- . yV
olk not
gu b ara
ed n
– Slowly lower engine ho and gearbox jack - V.A.G 1383 A- until 5- e o
ris te
pin connector foraut fuel delivery unit can be pulled off. ra
s c s
ce
e
– Lower fuel tank further. While doing so, rotate fuel tank and
nl
pt
du
feed filler neck between the leaf springs and the body.
an
itte
y li
erm
ab
Installing
ility
ot p
wit
, is n
h re
hole
spec
Caution
es, in part or in w
t to the co
is empty, as this may cause deflagrations.
rrectness of i
The fuel tank must contain at least 5 litres of fuel.
l purpos
♦ Install breather lines and fuel lines free of kinks.
nf
ercia
orm
♦ Do not interchange supply line and return line (return line blue,
m
atio
m
supply line black).

o
n in
or c
thi
♦ Ensure that line connections are tight.
te
sd
iva
o
r
♦ After installing fuel tank, check that the supply, return and
rp
cu
o
m
breather lines are still clipped onto the fuel tank.
f
en
ng
t.
yi Co
op
♦ Bleeding fuel system ⇒ page 140 .
C py
t. rig
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yri by
Specified torques
op Vo
by c lksw
cted agen
Prote
♦ ⇒ “1.1 Assembly overview - fuel tank”, page 98
AG.
1. Fuel tank 101

wage es n
Caddy 2011 ➤ yV
olks ot g
b ua
4-cylinder injection engine ir se (1.6 l engine, BiFuel) - Edition 12.2015ante
d r
tho eo
au ra
c
ss
2 Fuel delivery unit, fuel gauge sender
ce
e
nl
pt
du
an
itte
y li
⇒ “2.1 Removing and installing the fuel delivery unit”, page 102
erm
ab
ility
ot p
⇒ “2.2 Installation position of fuel delivery unit”, page 104
wit
, is n
h re
⇒ “2.3 Removing and installing the fuel gauge sender G ”,
hole
page 104
spec
es, in part or in w
t to the co
2.1 Removing and installing the fuel delivery
unit
rrectness of i
l purpos
♦ Union nut tool - 3217-
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.
♦ Torque wrench - V.A.G 1332-
Removing
Note
♦ Note safety precautions before beginning work ⇒ page 4 .

♦ Observe rules for cleanliness ⇒ page 7 .
– Remove fuel tank ⇒ page 99 .
WARNING
Fuel supply lines are under pressure! Wear eye protection and
protective clothing to avoid possible injury and skin contact.
Before loosening hose connections, wrap a cloth around the
joint. Then release the pressure by carefully pulling the hose
off the connection.

Caddy 2011 ➤
– Pull fuel lines -1- and -2- off the flange.
Note
Press in securing ring to release the fuel lines.
WARNING
A filled fuel tank must be placed on a level surface to ensure

the fuel delivery unit can be removed without danger. Wear eye
protection and protective clothing to avoid possible injury and
skin contact.
– Open locking ring using union nut wrench - 3217- .

– Pull the delivery unit and the oil seal out of the opening in the
fuel tank.
Installing
Note lkswage es n
o ot g
byV ua
d ran
ir se tee
♦ When inserting the fuel delivery unit, uensure
tho that the fuel or
gauge sender - G- is not bent. ss
a ac
ce
le
♦ Insert seal for fuel delivery unit dry into opening of fuel tank.
un
pt
an
d
itte
y li
♦ Moisten seal with fuel only when installing fuel delivery unit.
erm
ab
ility
ot p
♦ Do not interchange supply and return lines.
wit
is n
h re
ole,
spec
Observe markings -arrows- on fuel delivery unit and fuel tank
t to the co
– Push on fuel lines -1- (blue return line) and -2- (black supply
line).
rrectne
Specified torques
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
2. Fuel delivery unit, fuel gauge sender 103

Caddy 2011 ➤
2.2 Installation position of fuel delivery unit

Observe markings -arrows- on fuel delivery unit and fuel tank
The fuel delivery unit can only be removed or installed with the
fuel tank removed.
Note
AG. Volkswagen
♦ The fuel delivery unit flange
lksw can only be installed
agen AG do
esin
n this posi‐
tion. db
yV
o ot g
ua
ran
e
ris tee
♦ After installing
uth fuel delivery unit flange, check that supply, re‐
o
or
turn and breather
ss
a lines are still clipped onto fuel tank. ac
ce
le
un
pt
Return line (blue or marked blue) -1-.
an
d
itte
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erm
ab
Black supply line -2-
ility
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wit
is n
2.3 Removing and installing the fuel gauge
h re
ole,
spec
sender - G-
t to the co
Removing
– Remove fuel delivery unit ⇒ page 102 .
rrectne
– Release connectors for lines -1- and -2- and pull them off.
ss
– Lift securing tabs -3- and -4- using a screwdriver and pull off
o
cial p
fuel gauge sender - G- downwards -arrow-.

inform
mer
Installing
atio
m

o
n
c
i
or
n thi
e
– Insert fuel gauge sender - G- into guides on fuel delivery unit

t
sd
va
and press upwards until it engages.

i
o
pr
cum
r
fo
en
ng
– Clamp connector and ensure secure engagement.

t.
yi Co
op py
– Install fuel delivery unit ⇒ page 102 .
. C rig
ht ht
rig by
py Vo
Specified torques
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
3 Fuel filter
⇒ “3.1 Assembly overview - fuel filter”, page 105 agen AG. Volkswagen AG do
w es n
olks ot g
⇒ “3.2 Removing and installing the fuel filter”,
ed
by V page 106 ua
ra
is nte
or
3.1 Assembly overviewut - fuel filter
h eo
ra
sa s c
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un
pt
an
d
1 - Fuel filter
itte
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erm
ab
❑ Direction of flow is
ility
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marked with arrows.
wit
is n
❑ Do not interchange con‐
h re
ole,
nections.
spec
❑ Installation position: pin
t to the co
on filter housing must
engage in notch of guide
on filter bracket.
rrectne
⇒ page 106
❑ Removing and instal‐
s
ling. ⇒ page 106
s o
cial p
f in
2 - Retaining clip
form
mer
❑ For fuel pressure regu‐
atio
m
lator
o
n
c
i
or
n
3 - Fuel supply line
thi
te
sd
va
❑ Black
i
o
pr
cum
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fo
❑ From fuel tank.
en
ng
t.
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❑ To pull off, press release Cop py
. rig
button on connection.
ht ht
rig by
copy Vo
lksw
4 - Fuel return line
by
cted agen
Prote AG.
❑ Blue
❑ To fuel tank.
❑ To pull off, press release
button on connection.
5 - Fuel pressure regulator
❑ 4 bar
6 - Seal
7 - O-ring
8 - Fuel supply line
❑ Black
❑ To engine
❑ To pull off, press release button on connection.
9 - Bolt
❑ 3 Nm
10 - Bracket
❑ For fuel filter
❑ Secured to fuel tank.
3. Fuel filter 105

Caddy 2011 ➤
3.2 Removing and installing the fuel filter

AG. Volkswagen AG d
Special tools and workshop equipment required lksw
agen oes
not
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by
♦ Drip tray for fuel rised ara
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Removing aut ra
ss c
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Observe safety precautions ⇒ page 4 .
nl
pt
du
an
itte
Observe rules for cleanliness ⇒ page 7 .
y li
erm
ab
ility
– Place tray under fuel filter. ot p
wit
, is n
h re
hole
WARNING
spec
es, in part or in w
t to the co
Fuel system is under pressure! Wear eye protection and pro‐
rrectness of i
connection.
l purpos
nform
ercia
– Pull off fuel lines -1-, -2- and -3- by pressing release button.
m
at
om
ion
c
– Remove fuel filter.
in t
or
his
ate
Installing
do
priv
cum
or

f
en
ng
t.
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op
Direction of flow is indicated with an arrow on the filter housing.
C py
t. rig
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yri by
– Bleeding fuel system ⇒ page 140 .
op Vo
by c lksw
cted agen
Prote AG.
Installation position
Pin -2- on filter housing must engage in notch of guide -1- on filter
bracket.
Specified torques
♦ ⇒ “3.1 Assembly overview - fuel filter”, page 105

Caddy 2011 ➤
4 Autogas system
⇒ “4.1 Emptying fuel tank”, page 107
⇒ “4.2 Emptying the gas line”, page 109
⇒ “4.3 Renewing filter on the Autogas system”, page 110
⇒ “4.4 Removing and installing the fuel tank (Autogas)”,
page 113
⇒ “4.5 Components on fuel tank”, page 115
⇒ “4.6 Removing and installing gas injector”, page 122
⇒ “4.7 Removing and installing pressure and temperature sensor
for gas rail GX21 ”, page 123
⇒ “4.8 Checking SERTO adapter leads for leaks”, page 123
4.1 Emptying fuel tank
Note agen
AG. Volkswagen AG d
oes
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b ar
If the customerise is given a service appointment and itanis teeknown
d
♦ or
that a tank
aut valve will have to be replaced, the customer should
h or
ac
drive sthe
s vehicle until the gas tank is empty before bringing the
vehicle in for service.
ce
e
nl
pt
du
an
itte
♦ Even if the fuel tank indicator shows empty, there is still some
y li
erm
ab
residual liquid gas in the fuel tank depending on the set gas
ility
ot p
pressure limit. The residual liquid gas must be removed en‐

wit
, is n
tirely!
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
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.
4. Autogas system 107

Caddy 2011 ➤
Safety area
A - Wind direction
B - At least 10 m
C - At least 20 m
The safety area is to be closed off with barrier tape and the access
points are to be marked clearly with a warning that there is a dan‐
ger of the gas exploding.
WARNING
Autogas is heavier than air!

There must be no cavities in the ground (e.g. depressions, pits,
channels, cellars or other hollow areas into which the gas can
flow) in the working area.
There must be no ignition sources present, e.g. exposed flame,
sparks, electrostatic discharge or hot surfaces, that could
cause the Autogas to ignite.
Note
♦ It must be ensured that no gas enters buildings further away,

e.g. through open windows and doors.agen In addition, the
olksw
AG. V agen AG
area
does
ksw
must be easily accessible and
by Vwell ventilated (not a back yard).
ol not
gu
a d ran
se
♦ The wind direction is to
thobe taken into account.
ri tee
or
au ac
ss
Way of emptying Autogas cylinder:
ce
le
un
pt
an
d
itte
y li
rm
ab
WARNING
pe
ility
ot
wit
, is n
It is forbidden to empty Autogas tanks indoors!

h re
hole
spec
There is a danger of explosion and injury!

es, in part or in w
t to the co
Always empty fuel tanks outdoors!

rrectness of i
♦ Normal tank emptying equipment or liquid-gas burner devel‐

oped for LPG
l purpos
For use, see ⇒ corresponding instructions

nform
ercia
or
m
♦ Allow to escape into the atmosphere

com
tion in
r
– Empty the gas line ⇒ page 109 .

te o
thi
s
iva
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cum
WARNING
fo
en
ng
t.
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op
There is a danger of injury due to escaping gas.
C py
t. rig
gh ht
yri by
The system is pressurised. cop Vo
by lksw
cted agen
Prote
Wear suitable protection such as eye protection and protective
AG.
gloves.
Before opening the system place a cloth around the connec‐
tion. Then release pressure by carefully loosening the connec‐
tion.

Caddy 2011 ➤
– Remove fuel tank (Autogas) ⇒ page 113 and place it in the

safety area.
–
– Make up drainage pipe.
Drainage pipe consists of:
♦ Certified copper gas pipe or hose pipe with copper ends and
a pipe union . Volkswage n AG n AG d
wage oes
♦ Outer diameter: max.
yV
o6
lksmm not
gu
b ara
ed
♦ Length approx.
ho 12 m
ris nte
eo
t
au ra
– Set up safety
ss area ⇒ page 108 . c
ce
le
un
pt
– Route drainage pipe so there are no kinks and connect it to
an
d
itte
the gas tank valve - N495- .
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Take wind direction into account.
es, in part or in w
t to the co
WARNING
rrectness of i
In accordance with the safety requirements and regulations
l purpos
applicable to the use of Autogas systems, never leave the ve‐

hicle unsupervised!
nform
mercia
a
com
– Connect gas tank valve - N495- to magnetic release tool -

ion in
T10349- .
r
te o
thi
s
iva
Tank emptying begins.

do
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rp
cum
fo
en
ng
4.2 Emptying the gas line

t.
yi Co
Cop py
ht. rig
rig ht
py by
o Vo
WARNING by c lksw
cted agen
Prote AG.
Autogas is heavier than air!

There must be no cavities in the ground (e.g. depressions, pits,
channels, cellars or other hollow areas into which the gas can
flow) in the working area.
There must be no ignition sources present, e.g. exposed flame,
sparks, electrostatic discharge or hot surfaces, that could
cause the Autogas to ignite.
– Connect ⇒ Vehicle diagnostic tester -arrow-.

– Start the engine and switch it to gas mode.
– On ⇒ Vehicle diagnostic tester, select function Read and re-
lease rail pressure .
The engine stops once the rail pressure has decreased.

Caddy 2011 ➤
4.3 Renewing filter on the Autogas system

⇒ “4.3.1 Renewing the gas filter”, page 110
⇒ “4.3.2 Renewing the paper filter on the vaporiser”, page 110
4.3.1 Renewing the gas filter

Removing
WARNING
There is a danger from escaping gas.

The system is pressurised.
tion.
gloves.
– Unscrew lower filter housing -in the direction of the arrow- and
remove it straight downwards.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
– Remove filter -1- upwards
ss a out of the lower filter housing. c
ce
le
– Clean away any dirt on the filter housing.

un
pt
an
d
itte
y li
Installing
erm
ab
ility
ot p
– Renew seal in lower filter housing.

wit
is n
h re
– Insert new filter with new seal vertically into lower filter hous‐
ole,
spec
ing.
t to the co
– Screw lower filter housing in again up to the stop.

– Carry out a gas system test (GAP) once installation is com‐
plete ⇒ Maintenance ; Booklet 39 .
rrectnes
4.3.2 Renewing the paper filter on the vapor‐

s o
cial p
iser
inform
mer
Removing
atio
om
n
c
– Empty the gas line ⇒ page 109

or
n thi
te
sd
a
– Remove air filter with air filter housing ⇒ Rep. gr. 24 ; As‐
iv
o
pr
sembly overview - air filter .

um
r
fo
en
ng
t.
yi
– Remove battery - A- and battery tray ⇒ Electrical system; Rep.
Co
op py
gr. 27 ; Removing and installing battery .
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
WARNING
There is a danger from escaping gas.

gloves.
tion.
– Carefully undo the screwed connection -arrow- on gas line

-1- at the gas inlet of the filter housing and wait until the resid‐
ual gas has escaped.
– Then unscrew screwed connection on gas line -1- fully and lay
the gas line to one side.
wage e
– Disconnect connectory-2-
Vol on gas mode high-pressureotvalve
ks sn
gu -
N372- -1-. ised b ara
n r tee
ho
aut or
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
– Undo the screwed connection -arrow- of the filter housing with

rrectness of i
the gas mode high pressure valve - N372- and remove the
filter housing.
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
111
cted agen
Prote AG.
4. Autogas system
Caddy 2011 ➤
– Using circlip pliers, remove circlip -arrow- from filter housing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Remove the filter housing cover-4- and remove the filter ele‐
ce
le
un
pt
ment -3-.
an
d
itte
y li
rm
Installing
ab
pe
ility
ot
– Check seal in the filter housing for damage. This must be re‐
wit
, is n
placed if necessary.
h re
hole
spec
– Insert new paper filter-4-.
es, in part or in w
t to the co
Note
rrectness of i
♦ Note the installation position of tappet -2-.
l purpos
♦ The tappet must be inserted as shown in the picture.
nform
ercia
– Press the filter housing cover -4- up to the stop in the solenoid
m
valve -1- and secure it with a circlip -5-.
a
com
tion in
r
te o
thi
s
Note
iva
do
r
rp
cum
fo
Do not damage seal of filter housing.

en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri by
– Mount the gas mode high pressure valve - N372- on the va‐
op Vo
by c lksw
poriser using the 19 AF insert tool - T10455- . cted agen
Prote AG.
Note
Ensure that you install the gas mode high-pressure valve - N372-
in the correct installation position.

Caddy 2011 ➤
– Connect the gas line -1- to the gas inlet -arrow- of the filter
housing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
– Mount plug connector -2- on the gas mode high-pressure
es, in part or in w
valve - N372- -1-.
t to the co
– Install battery carrier.
rrectness of i
– Install battery ⇒ Electrical system; Rep. gr. 27 ; Disconnecting
and reconnecting battery .
l purpos
– Install air filter with air filter housing ⇒ Rep. gr. 24 ; Assembly
overview - air filter .
nform
ercia

m

com
tion in
r
– Read event memory using ⇒ Vehicle diagnostic tester. Repair

te o
thi
any faults according to repair guidelines.

s
iva
do
r
rp
cum
Specified torque
fo
en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri
Vaporiser 30 Nm
p by
o Vo
by c lksw
cted
Steel gas line 21 Nm
agen
Prote AG.
4.4 Removing and installing the fuel tank

(Autogas)
Removing
♦ Engine and gearbox jack - V.A.G 1383 A-
– Empty the gas line ⇒ page 109

Caddy 2011 ➤
WARNING

gloves.
tion.
– Carefully disconnect gas lines -1 and 2-.

– Disconnect connector at fuel tank.
– Undo nuts -arrow- and lower the fuel tank using the engine
and gearbox jack - V.A.G 1383 A- .
Installing agen
AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
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
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
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Place the fuel tank on the vehicle using the engine and gear‐
box jack - V.A.G 1383 A- .
– Tighten nuts -arrows-.

G. Volkswagen AG d
– Tighten gas lines -1- and -2-. lkswagen A oes
not
o
yV gu
– Reconnect connector. ised b ara
nte
r
t ho eo
– Carry out a gas system
au test (GAP) once installation is com‐ ra
c
ss ; Booklet 39 .
plete ⇒ Maintenance
ce
le
un
Specified torque pt
an
d
itte
y li
rm
Component Specified torque ab

pe
ility
ot
wit
Nut for fuel tank (liquefied pe‐ 30 Nm
, is n
h re
troleum gas)
hole
spec
Gas line -1- 21 Nm

es, in part or in w
t to the co
Gas line -2- 28 Nm

rrectness of i
4.5 Components on fuel tank

l purpos
⇒ “4.5.1 Removing and installing upper covers ”, page 115

⇒ “4.5.2 Removing and installing the lower cover”, page 116
nform
ercia
⇒ “4.5.3 Sealing upper and lower covers”, page 117

m
a
com
tio
⇒ “4.5.4 Removing and installing safety valve”, page 119

n in
r
te o
thi
⇒ “4.5.5 Removing and installing the G707 gas gauge sender”,

s
iva
do
page 120
r
rp
cum
fo
en
g
⇒ “4.5.6 Removing and installing fuel gauge sender”, page 121

n
t.
yi Co
op py
⇒ “4.5.7 Removing and installing fill-stop valve”, page 121
t. C rig
gh ht
pyri by
Vo
o
4.5.1 Removing and installing upper covers
c by lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Removing thor eo
au ra
c
– Removing fuel tank (Autogas) ⇒ page 113 . ss
ce
le
un
pt
– Unscrew bolts -arrows-, unclip connector and lever off cover
an
d
itte
y li
-1- using removal wedge - 3409- .
rm
ab
pe
ility
Installing
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Always renew upper cover.
rrectness of i
l purpos
– Seal upper cover ⇒ page 117 .

Specified torque
nform
ercia

m
a
com
tio
M6 bolts for upper cover 7 Nm
n in
r
te o
thi
s
iva
do
4.5.2 Removing and installing the lower cover
r
rp
cum
fo
en
ng

t.
yi Co
Cop py
t. rig
♦ Removal wedge - 3409- opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.
Removing
– Removing the upper cover ⇒ page 115

Caddy 2011 ➤
– Unscrew bolts -arrows- and lever off cover -1- using removal
wedge - 3409- .
Installing
Install in reverse order. In the process, note the following:
– Seal lower cover ⇒ page 117 .
Note
♦ Leakage test must be performed following installation of the

cover.
♦ Always renew the seals on the bolts -arrow- and the cover.
– Carry out leakage test ⇒ page 123 .

Specified torque
M6 bolts for lower cover 7 Nm
M4 bolts for washers 1.8 Nm
4.5.3 Sealing upper and lower covers AG. Volkswagen AG d

agen oes
lksw not
Special tools and workshop equipment requiredby V o gu
ara
ed
ris nte
♦ Silicone adhesive sealant - D 176 501 uA1-
tho eo
ra
s a c
♦ Loctite 242 s
ce
le
un
pt
♦ Loctite 222
an
d
itte
y li
rm
ab
♦ Loctite 7063
pe
ility
ot
wit
– Removing fuel tank (Autogas) ⇒ page 113 .
, is n
h re
hole
Sealing lower cover:
spec
es, in part or in w
– Removing and installing lower cover ⇒ page 116 .

t to the co
– Clamp lower cover in a holding device. rrectness of i
Note
l purpos
♦ Thoroughly clean O-ring grooves, bolts, blind holes and and

nform
ercia
contact surfaces using Loctite 7063 .

m
♦ Thoroughly clean threads and blind holes with compressed

com
tion in
air.
r
te o
thi
♦ Wear gloves and ensure items are free of grease.

s
iva
do
r
rp
cum
♦ Bead thickness: at least 2.5 mm

fo
en
ng
t.
yi Co
♦ Application life of silicone sealant, max 15 minutes. ht. Cop py
rig
rig ht
py by
– Thoroughly clean sealing surfaces using Loctite 7063 .
co Vo
by lksw
cted agen
Prote AG.
Note
Sealing surfaces must be grease-free.

Caddy 2011 ➤
– Apply silicone adhesive sealant - D 176 501 A1- to clean seal‐

ing surface -arrows- of lower cover -1-.
– Fit suitable O-ring in groove and press in evenly. Now, apply
a bead of approx. 2.5 mm silicone adhesive sealant - D 176
501 A1- over fitted O-ring.
WARNING
♦ Apply locking fluid to threads in blind holes (down to bot‐

tom of threaded hole).
♦ Locking fluid must not be applied to threads of bolts, this
can cause an air lock at the bottom of the threaded hole
and the locking fluid will not harden.
♦ Do not apply locking fluid to O-ring sealing seat, otherwise
the sealing capability of the O-ring is destroyed.
– Squirt Loctite 242 into all 4 blind bolt holes -top arrows- and
Loctite 222 into blind washer holes -bottom arrows-.
– Fit lower cover on gas tank, and tighten M6 bolts.
– Tighten M4 washer bolts.
Sealing upper cover:
– Removing and installing upper cover ⇒ page 115 .
– Clamp upper cover in a holding device.
Note
♦ Always renew upper cover. AG. Volkswagen AG d

agen oes
lksw not
♦ Thoroughly clean O-ring by V grooves, bolts, blind holes and
o guand
ara
contact surfaces ousing
ris
ed
Loctite 7063 . nte
h eo
ut ra
♦ Thoroughly clean
ss a threads and blind holes with compressed c
air.
ce
le
un
pt
an
d
♦ Wear gloves and ensure items are free of grease.

itte
y li
rm
ab
♦ Bead thickness: at least 2.5 mm

pe
ility
ot
wit
, is n
♦ Application life of silicone sealant, max 15 minutes.

h re
hole
spec
– Thoroughly clean sealing surfaces using Loctite 7063 .

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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Apply silicone adhesive sealant - D 176 501 A1- uniformly to

clean O-ring groove -arrows-.
– Fit suitable O-ring in groove and press in evenly. Now, apply
a bead of approx. 2.5 mm silicone adhesive sealant - D 176
501 A1- over fitted O-ring.
WARNING
♦ Apply locking fluid to threads in blind holes (down to bot‐

tom of threaded hole).
♦ Locking fluid must not be applied to threads of bolts, this
can cause an air lock at the bottom of the threaded hole
and the locking fluid will not harden.
♦ Do not apply locking fluid to O-ring sealing seat, otherwise
the sealing capability of the O-ring is destroyed.
gen AG
. Volkswagen AG
d a oes
ksw not
y Vol gu
b ara
ed nte
ris
– Reinstall cover, and tighten M6tho bolts. eo
au ra
c
– Carry out a gas ss (GAP) once installation
system test is com‐
ce
le

un
pt
an
d
itte
y li
Specified torque
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
4.5.4 Removing and installing safety valve
Removing
ss o
cial p
f
– Removing the fuel tank (Autogas) ⇒ page 113 . inform
mer
– Draining fuel tank (Autogas) ⇒ page 107

atio
om
– Removing the upper cover ⇒ page 115 .

n
c
i
or
n thi
e
– Removing the lower cover ⇒ page 116 .

t
sd
iva
o
pr
cum
r
fo
en
ng
WARNING yi
t.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
The system is pressurised. cted agen
Prote AG.

gloves.
tion.

Caddy 2011 ➤
– Remove bolts -arrows-.

– Pull the pressure relief valve out of the fuel tank.
Installing
Install in reverse order. While doing so, note the following:
gen AG
. Volkswagen AG
a does
ksw not
– “OP▲Top” must be at top. Vol gu
d by ara
e nte
ris
– Always renew the seal on the pressure
tho relief valve. eo
au ra
c
ss
– Tighten bolts -arrows- in diagonal sequence.
ce
e
nl
pt
du
– Seal covers ⇒ page 117 .
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Specified torque
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
troleum gas)
m
at
om
ion
c
4.5.5 Removing and installing the - G707- gas
in t
or
his
te
gauge sender
a
do
priv
cum
or
Removing
f
en
ng
t.
yi Co
op
– Removing the fuel tank (Autogas) ⇒ page 113 .
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
– Unscrew bolts -arrow - and eject line from the plug.
Installing
– “Top” must be at top.
– Tighten bolts -arrows-.
Specified torque
troleum gas)

Caddy 2011 ➤
4.5.6 Removing and installing fuel gauge

sender
Removing
– Removing gas gauge sender - G707- -1- ⇒ page 120
WARNING

The system is pressurised. . Volkswagen AG
gen AG does
swa
Wear suitable protection such as eye protection and protective yV
olk not
gu
gloves. rised b ara
nte
tho eo
Before opening the system place a cloth around the s auconnec‐ ra
c
tion. Then release pressure by carefully loosening the
s connec‐
ce
e
tion.
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unscrew bolts -arrow- and pull out fuel gauge sender.
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
– Tighten bolts -arrows- in diagonal sequence.
rrectness of i
l purpos

nform
ercia

m
at
om
i
Specified torque
on
c
in t
or
his
e

at
do
priv
c
um
for
en
ng
t.
M6 bolts for lower cover 7 Nm Cop
yi Co
py
M4 bolts for washers 1.8 Nm ht. rig
rig ht
py by
co Vo
by lksw
cted agen
troleum gas) Prote AG.
4.5.7 Removing and installing fill-stop valve

Removing

Caddy 2011 ➤
WARNING

gloves.
tion. Then release pressure by carefully loosening the connec‐ agen
AG. Volkswagen AG d
tion.
oes
olksw not
y V gu
d b ara
rise nte
tho eo
u ra
– Remove bolts -arrows-. ss a c
ce
e
nl
– Pull the inlet valve out of the fuel tank.
pt
du
an
itte
y li
Installing erm
ab
ility
ot p
wit
, is n
h re
– Always renew seal on the inlet valve.
hole
spec
es, in part or in w
t to the co
– Tighten bolts -arrows-.
rrectness of i
l purpos

nf
ercia
or
Specified torque
m
m
atio
om
n in
or c
thi
e

t
sd
iva
o
r
rp
cu
o
m
f
en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri
troleum gas)
p by
co Vo
by lksw
cted agen
Prote AG.
4.6 Removing and installing gas injector
WARNING
Gas can escape when loosening the gas rail. Wear eye pro‐
tection and protective clothing to avoid eye injuries and burns.
Cover separating points with a cloth and open carefully.
– Disconnect connectors on the gas injectors gas injector 1 -

N366- , gas injector 2 - N367- , gas injector 3 - N368- and gas
injector 4 - N369- .

Caddy 2011 ➤
– Loosen bolts -arrows-.

– Remove cover plate and renew defective gas injector.
Allocation of gas injectors:
♦ Gas injector 1 - N366- , cylinder 1
4.7 Removing and installing pressure and

temperature sensor for gas rail - GX21-
WARNING
Gas can leak out when loosening pressure and temperature

sensor for gas rail - GX21- . Wear eye protection and protective
clothing to avoid eye injuries and burns. Cover separating
points with a cloth and open carefully.
– Disconnect connector -1-.

Installing
olkswagen AG
– Carry out a gas system test (GAP) once installation
agenis com‐
AG. V does
ksw
plete ⇒ Maintenance ; Booklet 39 . by
Vol not
gu
ara
ed nte
Specified torque ris
tho eo
au ra
c
ss
ce
le
un
pt
Bolt -2- 8 Nm
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
4.8 Checking SERTO adapter leads for leaks

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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fo
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ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤

equipment required
♦ Magnetic release tool -
T10349- AG. Volkswagen AG d
agen oes
ksw
♦ Gas leak tester for natural by
Vol not
gu
ara
gas vehicles - VAS 6227- rised
nte
ho eo
ut
♦ Adapter for gas leak detec‐ ss a ra
c
tor - VAS 6227/1-
ce
e
nl
pt
du
an
♦ Leak detector spray (com‐
itte
y li
mercially available)
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
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Leakage test of SERTO adapter leads is necessary following re‐

moval of following components:
♦ Adapter leads to fuel tank
♦ Solenoid valve
♦ Safety valve
♦ Fill-stop valve
♦ Gas gauge sender - G707-
Note
♦ When the cover, the lines or the valve are removed, leaks may
occur in the corresponding area.
♦ The leakage test of the SERTO adapter leads does not replace
the gas system test (GAP).
♦ Following the leakage test of the SERTO adapter leads, as
well as upon completion of any work on the gas system, the
gas system test (GAP) must be performed.
♦ When working on the autogas system, always ensure for tidi‐
ness and cleanliness.

Caddy 2011 ➤
DANGER!
♦ Gas system tests must only be performed by specially

trained personnel trained at regular intervals.
♦ Autogas is highly inflammable and, in combination with air,
creates a combustible mixture.
♦ There must be no open flame or source of ignition near
the autogas system.
♦ Inhaling autogas can lead to light-headedness and lung
damage. High concentrations may lead to suffocation due
to lack of oxygen.
♦ Autogas is not odourless because substances having a
strong odour are added.
Test precondition
• Fuel tank is 50 % full (legislation)
• All parts of autogas system to be checked are easily accessi‐
ble
• No entries in event memory of autogas control unit
• Working environment free of draught
Procedure
– Connect adapter for gas leak detector - VAS 6227/1- to lines
-1-. wage
e
olks s no
yV t gu
edb ara
ris nte
tho eo
au ra
c
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
– Fit magnetic release tool - T10349- to solenoid valve -1-.

rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
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.

Caddy 2011 ➤
– Using gas leak detector - VAS 6227- , check all components,

connections and lines for leaks.
Note
When leak detection spray is being used, it must be ensured that

no bubbles come out of the sprayed area within 3 minutes.
If leaks have been detected:

– Locate and rectify leaks.
– Then, repeat leakage test using gas leak detector - VAS
6227- .
If no leaks have been detected:
– Remove magnetic releaseatool
gen A-GT10349- from
. Volkswagen AG solenoid valve.
d w oes
olks no
– Unscrew adapter for
d b gas leak detector - VAS 6227/1- u. ar
yV tg
e an
ris tee
– Install upper ucover
tho ⇒ page 115 . or
a ac
ss
– Install fuel tank ⇒ page 113 .
ce
e
nl
pt
du
an
itte
plete ⇒ Maintenance ; Booklet 39 . 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
orm
m
atio
om
n in
or c
thi
te
sd
iva
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
5 Accelerator mechanism
⇒ “5.1 Function”, page 127 AG. Volkswagen AG d
agen oes
ksw
⇒ “5.2 Assembly overview by V- accelerator mechanism”, page
ol not
gu127
ara
ed
is nte
⇒ “5.3 Removing and hor installing the accelerator module”, eo
ut
page 128 ss a ra
c
ce
le
5.1 Function
un
pt
an
d
itte
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With the EPC system, the throttle valve is not operated by a cable
erm
ab
ility
from the accelerator There is no mechanical connection between
ot p
wit
the accelerator and the throttle valve.
is n
h re
ole,
The position of the accelerator is transmitted to the engine control
spec
unit by 2 accelerator position senders (variable resistors together
t to the co
in one housing) connected to the accelerator.
The position of the accelerator (driver's requirement) is a main
input value for the engine control unit.
rrectne
The throttle valve is actuated by a control motor (throttle valve
positioner) in the throttle valve module over the full range of en‐
ss o
gine speeds and load conditions.
cial p
f inform
The throttle valve is operated by the throttle valve positioner which
mer
is controlled by the engine control unit.
atio
om
n
c
When the engine is not running and the ignition is switched on,
i
or
n thi
the engine control unit moves the throttle valve exactly as pre‐
te
sd
va
scribed by the accelerator position sender. This means that when

i
o
pr
c
the accelerator is depressed half way, the throttle valve positioner
um
r
fo
en
ng
opens the throttle valve to the same extent. The throttle valve is
t.
yi Co
then approx. half open. Cop py
ht. rig
rig ht
When the engine is running (under load), the engine control unit py by
co Vo
lksw
can open or close the throttle valve independently of the accel‐
by
cted agen
Prote
erator position sender.
AG.
This means that the throttle valve can already be fully open even
though the accelerator is only depressed half way. This has the
advantage of preventing throttling losses at the throttle valve.
After evaluating the torque requirements of various components
(e.g. air conditioning system, automatic gearbox, ABS/ESP), the
engine control unit calculates the optimal throttle valve opening
angle for the respective situation.
This also results in significantly improved consumption and ex‐
haust emission values under certain load conditions.
“EPC” is a system comprising all components which contribute to
determining, controlling or monitoring the position of the throttle
valve, e.g. accelerator position senders, throttle valve control
module, electronic power control warning lamp and engine control
unit.
5.2 Assembly overview - accelerator mechanism
5. Accelerator mechanism 127

Caddy 2011 ➤
1 - Connector
❑ Black
❑ 6-pin
2 - Accelerator position sender
- G79- with accelerator posi‐
tion sender 2 - G185-
❑ Not adjustable.
❑ -A- openings for release
tool - T10269- or release
tool - T10297-
⇒ page 128
3 - Bolt
❑ 10 Nm AG. Volkswagen AG d
agen oes
4 - Cap olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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
nform
mercia
a
com
tion in
r
te o
thi
5.3 Removing and installing the accelerator
s
iva
do
r
module
rp
cum
fo
en
ng
t.
yi
Co
Cop py
t. rig
gh ht
♦ For left-hand drive vehicles: release tool - T10238- yri
p by
o Vo
by c lksw
cted agen
Prote AG.
or

Caddy 2011 ➤
♦ For right-hand drive vehicles: release tool - T10240-
– Remove cover for steering column -arrows-.

– Lever cover cap ⇒ Item 4 (page 128) out with a screwdriver.
– Unscrew securing bolt ⇒ Item 3 (page 128) .
– Push release tool - T10238- (for right-hand drive vehicles re‐

lease tool - T10240- ) into intended holes as shown to stop
and remove accelerator module.
– Disconnect the electrical plug connector and pull away the line
routing at the accelerator module.
AG. Volkswagen AG d
agen oes
Installing Volksw not
gu
d by ar
Installation isoriscarried out in the reverse order; note theanfollowing:
e
tee
h
aut or
ac
ss
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
– Connect line routing -1- and electrical connector -2- on the

wit
is n
accelerator module.
h re
ole,
spec
– Push accelerator module onto pins -6-.

t to the co
– Insert centring pin -7- into bore on vehicle floor.

– Secure accelerator module with bolt -3-, and fit cap -4-.
rrectne
– Install cover for steering column again.

Specified torques
ss o
cial p
♦ ⇒ “5.2 Assembly overview - accelerator mechanism”,

inform
page 127
mer
atio
om
n
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
o
by c lksw
cted agen
Prote AG.
5. Accelerator mechanism 129

Caddy 2011 ➤
6 Activated charcoal filter system

⇒ “6.1 Function”, page 130
⇒ “6.2 Checking fuel tank breather”, page 130
6.1 Function
Fuel vapour forms above the surface of the fuel in the tank; the
quantity depends upon the air pressure and ambient temperature.
The activated charcoal filter system prevents these HC emissions
escaping to the atmosphere.
In limited quantities, fuel vapours pass from the highest point in
the tank through the gravity valve (which closes at an angle of
45°) and through a pressure retention valve into the activated
charcoal filter.
The activated charcoal stores these vapours like a sponge.
When the car is being driven and thewLambda gen AG control is
. Volkswagen Aactive
G do
s a es
(engine warm), the activated charcoal y Volk filter solenoid valve 1 - not gu
N80- , also known as regeneration
ris
ed
b
valve, is activated (pulsed) by arant
the engine control unit according
tho to load and engine speed. The ee
or
opening period depends s auon the input signals. ac
s
ce
le
During the purging procedure (regeneration of the activated char‐

un
pt
an
d
coal), the intake manifold vacuum draws in fresh air through the
itte
y li
breather opening on the underside of the activated charcoal can‐
erm
ab
ility
ister. The fuel vapours stored in the activated charcoal and fresh
ot p
wit
air are fed to combustion in metered quantities.
is n
h re
ole,
The pressure retention valve prevents fuel vapours from being spec
drawn from the fuel tank when the solenoid valve is open and t to the co
intake manifold vacuum is present. It thus ensures that the purg‐
ing of the activated charcoal filter has priority.
When not energised (e.g. open circuit), the solenoid valve is
rrectne
closed. The activated charcoal filter will not be purged.
6.2 Checking fuel tank breather

ss o
cial p
f in

form
mer
♦ Vacuum tester - V.A.G 1368-

atio
om
n
c
i
or
n thi
te
sd
iva
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.

Caddy 2011 ➤
♦ Hand vacuum pump - V.A.G 1390-
Test prerequisite
• Ignition must be switched off.
Test procedure
– First, disconnect the white breather hose on the hose connec‐
tion -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Then connect hand vacuum pump - V.A.G 1390- and vacuum

ility
ot p
tester - V.A.G. 1368- to the hose -1- as shown.

wit
, is n
h re
– Set vacuum tester - V.A.G. 1368- to -A/B- position.

hole
spec
es, in part or in w
– Operate hand vacuum pump - V.A.G 1390- several times.

t to the co
Vacuum must not build up.

If vacuum builds up:
rrectness of i
– Check breather hose -3- on activated charcoal filter -2- for

l purpos
soiling and clean if necessary.

If vacuum does not build up:
nf
ercia
– Hold breather hose -3- shut and operate vacuum pump again
rm
m
several times. Vacuum must build up.

atio
om
n in
c
If vacuum does not build up:

or
thi
te
sd
a
– Renew activated charcoal filter -2-.

iv
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.
6. Activated charcoal filter system 131

Caddy 2011 ➤
7 Fuel pump
⇒ “7.1 Checking fuel pump”, page 132
⇒ “7.1.1 Checking function and voltage supply”, page 132
⇒ “7.1.2 Checking the fuel delivery
wagerate”, page 134 does
n AG. Volkswagen AG
ks not
Vol gu
⇒ “7.1.3 Checking current
ed consumption”, page 137
by ara
nte
is
or eo
⇒ “7.1.4 Checking anon-return
ut
h
valve for fuel pump”, page 138 ra
ss c
7.1 Checking fuel pump
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
equipment required
wit
is n
h re
ole,
♦ Pressure gauge - VAS
spec
6550-
t to the co
♦ Remote control - V.A.G
1348/3A-
rrectne
♦ Test instrument adapter/
DSO (5-pin) - VAS 5565-
ss
♦ Multimeter - V.A.G 1715-
o
cial p
f in
♦ Special wrench - T10202-
form
mer
♦ Torque wrench - V.A.G atio

m
1332-
o
n
c
i
or
n thi
e
♦ Measuring container, ca‐

t
sd
va
pacity 2 litres
i
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.
7.1.1 Checking function and voltage supply

• Fuel pump relay - J17- OK
• Battery voltage at least 11.5 V
• Fuse for fuel pump OK. Fuse assignment ⇒ Current flow dia‐
grams, Electrical fault finding and Fitting locations

Caddy 2011 ➤
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV ua
Function of fuel pump is checked using ir se final control diagnosis.
d b ran
tee
tho
u or
a ac
ss
ce
le
un
pt
– Connect diagnosis cable connector to diagnostic connection
an
d
itte
in driver footwell.
y li
erm
ab
ility
ot p
wit
is n
– Select Final control diagnosis in Engine electron-
h re
ole,
ics .
spec
t to the co
– Press right arrow button ► on display to initiate actuation of
fuel pump.
Fuel pump must be actuated in pulses.
rrectne
– Switch off ignition.
ss
If fuel pump does not run:
o
cial p
f inform
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.
mer
72 ; Rear seats; Removing and installing bench seat .
atio
om
n
– Remove cover from the fuel delivery unit.
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.
– First check that the connector -arrow- is fitted securely by pull‐

ing connector without pressing catch. If connector was not
inserted correctly, repeat functional check of fuel pump.
– Pull off connector.
– Check contacts on plug and on fuel delivery unit for damage.
7. Fuel pump 133

Caddy 2011 ➤
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect multimeter - V.A.G 1715- to cables -1- and -5- of test
instrument adapter/DSO (5-pin) - VAS 5565- .
– Initiate final control diagnosis again. The voltage must now in‐
crease in pulses.
Voltage supply not OK:
– Locate and eliminate open circuit referring to current flow di‐
agram ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.
Voltage supply OK:
WARNING

connection.
– Pull fuel lines -1- and -2- off the flange.
Note
♦ Press in securing ring to release the Afuel lines.

G. Volkswagen n AG do
wage e
♦ On vehicles with auxiliary heater,
yV
olks the connector and thes fuel
not
gu
line of the metering pump
ris
ed - V54- must also be disconnected. ran
b a
t ee
ho
aut or
ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
– Open locking ring using wrench - T10202- .

ot p
wit
, is n
– Check that electrical wires between flange and fuel pump are
h re
hole
connected.
spec
es, in part or in w
If no open circuit can be found:

t to the co
– Fuel pump is defective, renew fuel delivery unit ⇒ page 102 .

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
7.1.2 Checking the fuel delivery rate

n in
or c
thi
te
sd
a
• Voltage supply OK.

iv
o
r
rp
cu
o
• Fuel pressure regulator and holding pressure OK, checking

f
en
ng
t.
yi
⇒ page 160
Co
Cop py
t. rig
• Fuel filter OK.
gh ht
pyri by
Vo
co lksw
by
– Remove cap from fuel filler neck. cted agen
Prote AG.
– Open cover of relay and fuse holder of engine compartment

E-box.

Caddy 2011 ➤
– Pull fuse SB33 out of socket F33 of fuse holder.

– Connect remote control - V.A.G 1348/3 A- with adapter cable
- V.A.G 1348/3-3- to right terminal of fuse socket F33.
– Tape off 2nd connector contact of the adapter cable -
V.A.G 1348/3-3- with insulating tape -arrow-
n Ato prevent
G. Volkswageshort
n AG d
circuits. wage oes
olks no
V t gu
by ara
– Connect crocodile clip to vehicle
ris battery (+).
ed nte
tho eo
s au ra
c
s
ce
Note
e
nl
pt
du
an
itte
y li
Delivery rate of fuel pump must be measured at 4 bar. Therefore,
erm
ab
test fuel pressure before measuring fuel delivery rate
ility
ot p
⇒ page 160 .
wit
, is n
h re
hole
spec
es, in part or in w
WARNING
t to the co
rrectness of i
l purpos
connection.
nf
ercia
orm
m
atio
m
– Pull the return line -1- off the fuel pressure regulator.
o
n in
or c
thi
te
sd
iva
Note
o
r
rp
cu
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ng
t.
Press in securing ring to release fuel line.
yi Co
Cop py
t. rig
gh ht
yri
– Connect adapter - VAS 6550/1- to fuel pressure regulator and
p by
o Vo
by c lksw
hold the end of the adapter in a measuring vessel. Prote
cted AG.
agen
– Operate remote control - V.A.G 1348/3A- for approx. 5 sec‐

onds to fill fuel filter.
– Drain measuring container.
– The delivery rate of the fuel pump depends on the voltage.
Therefore connect the multimeter to the battery.
– Operate remote control for 30 seconds and measure the bat‐
tery voltage.
7. Fuel pump 135

Caddy 2011 ➤
– Compare delivered quantity of fuel with specification.

*) Minimum delivery rate cm³/30 s
**) Voltage at fuel pump with engine not running and pump run‐
ning (approx. 2 volts less than battery voltage).
Example: agen
AG. Volkswagen AG d
oes
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V
During the test a voltage of ed 12.5
by volts is measured at the battery.
gu
ara
Because the voltage athotheris pump is approx. 2 volts less than the ntee
battery voltage, thisswill
au result in a minimum delivery rate of
t or
ac
580 cm³/30 s. s
ce
e
nl
pt
du
If minimum delivery rate is not attained:
an
itte
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erm
ab
– Check supply line to filter for possible restrictions (kinks) or
ility
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blockages.
wit
, is n
h re
If fuel line is OK
hole
spec
– Check fuel delivery rate before fuel filter. Proceed as follows
es, in part or in w
t to the co
to do this:
WARNING
rrectness of i
l purpos

nf
ercia
orm
connection.
m
atio
om
n in
or c
thi
te
sd
iva
– Pull fuel supply line -arrow- off fuel filter.

o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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by
cted agen
Prote AG.

Caddy 2011 ➤
– Connect pressure tester - VAS 6550- to fuel supply line with

adapter - VAS 6550/1- . Hold adapter - VAS 6550/2- in a
measuring container.
– Make sure that drain tap is closed and cut-off taps are open.
– Operate remote control - V.A.G 1348/3A- . Then slowly close
the shut-off tap -arrow- until a pressure of 4 bar is displayed
on pressure gauge. agen
From
AG. Vothis
lkswapoint
gen AGon do not move position
does
of shut-off tap.
Volksw not
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– Drain
ho
rmeasuring
is container. tee
t or
au a
– Operate
ss the remote control again for 30 seconds. Compare
c
the fuel delivery rate with the first measurement.
ce
e
nl
pt
du
an
itte
If the minimum delivery rate is now achieved:
y li
erm
ab
– Renew fuel filter.
ility
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wit
, is n
If the minimum delivery rate is again not achieved
h re
hole
spec
– Remove fuel delivery unit and check filter strainer for contam‐
es, in part or in w
ination.
t to the co
Only if still no fault has been detected:
– Renew fuel delivery unit ⇒ page 102 .
rrectness of i
– Reconnect all disconnected fuel lines.
l purpos
– Bleeding fuel system ⇒ page 140 . nform

ercia
7.1.3 Checking current consumption

m
at
om
ion
c
– Remove bench seat ⇒ General body repairs, interior; Rep. gr.

in t
or
his
e
72 ; Rear seats; Removing and installing bench seat .

at
do
priv
– Remove cover from the fuel delivery unit.

um
for
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t.
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Cop py
ht. rig
rig ht
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cted agen
Prote AG.
– First check that the connector -arrow- is fitted securely by pull‐

ing connector without pressing catch. The connector can
cause a fault if it has not been fitted correctly.
– Pull off connector.
– Check contacts on plug and on fuel delivery unit for damage.
7. Fuel pump 137

Caddy 2011 ➤
– Connect test instrument adapter/DSO (5-pin) - VAS 5565- to

connector and fuel delivery unit.
– Connect pick-up clamp -A- to red terminal with lettering “pick-
up clamp” for test instrument adapter/DSO (5-pin) - VAS
5565- .
– Start engine and run at idling speed.
– Measure current consumption of fuel pump.
• Specification: max. 9 amps.
Note
♦ The starting current for the fuel pump can be briefly above
specifications when starting the engine.
♦ If the fault in the fuel system is not always evident, the check
can also be carried out during a road test. A 2nd person is
required to do this, however.
If the current draw is exceeded:

– If the fuel pump is defective, renew fuel delivery unit
⇒ page 102 . G. Volkswage A n AG d
agen oes
olksw not
yV
7.1.4 Checking non-return valve for fuel pump
gu
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– Open cover of relay and fuse holder
ss au of engine compartment ra
c
E-box.
ce
le
un
pt
an
d
itte
y li
erm
ab
– Connect remote control - V.A.G 1348/3 A- with adapter cable
ility
ot p
- V.A.G 1348/3-3- to right terminal of fuse socket F33.

wit
is n
– Tape off 2nd connector contact of the adapter cable - h re

ole,
spec
V.A.G 1348/3-3- with insulating tape -arrow- to prevent short
circuits.
t to the co
– Connect crocodile clip to vehicle battery (+).

rrectne
WARNING
ss

o
cial p

inform

mer
atio
m
connection.
o
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
– Pull fuel supply line -arrow- off fuel filter.

fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Connect pressure tester - VAS 6550- to fuel supply

AG. Voline
lkswawith
gen AG
adapter - VAS 6550/1- . Hold adapter -olVASagen
ksw 6550/2- in a
does
not
measuring container. db
y V gu
ar
e an
ris tee
– Close pressure gauge - VAS u6550- tho shut-off tap -A- (lever at or
right angles to direction of flow).
ss a ac
ce
e
nl
– Operate remote control at short intervals until a pressure of
pt
du
an
approx. 4 bar has built up.
itte
y li
erm
ab
ility
ot p
WARNING
wit
, is n
h re
hole
Danger of spraying when opening the shut-off valve! Wear eye
spec
es, in part or in w
protection and protective clothing to avoid possible injury and
t to the co
skin contact. Hold container in front of open connection of
pressure tester.
rrectness of i
– Reduce excessive pressure by carefully opening shut-off tap.
l purpos
– Observe pressure drop on pressure gauge. After 10 minutes,

pressure must not drop below 3 bar.
nf
ercia
orm
If the pressure drops further:
m
atio
om
n in
– Check line connections for leaks.
or c
thi
te
sd
If no fault in lines is detected:
iva
o
r
rp
cu
– If the fuel pump is defective, renew fuel delivery unit.
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
7. Fuel pump 139

Caddy 2011 ➤
24 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Technical data”, page 140
⇒ “1.2 Bleeding the fuel system”, page 140
1.1 Technical data

Engine code CHGA
Idling check
Idling speed4) rpm 600 … 920
Engine control unit 5)
System designation SIMOS 7PP

Part number ⇒ Electronic Parts Catalogue
Governed speed rpm approx. 6500
4) If voltage supply to engine control unit drops below 12 volts, idling speed will
be raised gradually up to 1020 rpm. The idling speed cannot be adjusted.
AG. Volkswagen AG d
swagen oes
5) Renew engine control unit. ⇒ pagey V 163
olk not
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1.2 author
Bleeding the fuel system eo
ra
ss c
ce
le
un
pt
Note
an
d
itte
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rm
ab
pe
♦ To avoid damaging the catalytic converter, the fuel system

ility
ot
must be bled without the return line following work on fuel lines
wit
, is n
h re
or fuel filter. Do not start the engine until the fuel system has
hole
been bled.
spec
es, in part or in w
♦ Observe rules for cleanliness ⇒ page 7 .

t to the co

rrectness of i
♦ Diesel extractor - VAS 5226-

l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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Cop py
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by
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Prote
♦ Adapter - V.A.G 1318/20-
AG.
♦ Adapter - V.A.G 1318/20–1-

♦ Vehicle diagnostic tester
140 Rep. gr.24 - Mixture preparation - injection

Caddy 2011 ➤
WARNING
. Volkswagen AG
gen AG does
swa
Fuel supply line is pressurised. Wear by
Voeye
lk protection and pro‐ not
gu
tective clothing to avoid possiblerisinjury
ed and skin contact. Before ara
nte
loosening hose connections, thowrap a cloth around the joint. eo
Then release the pressuressbyau carefully pulling the hose off the ra
c
connection.
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unscrew cover cap -arrow- of bleed valve.
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
orm
– Turn valve (on the T-piece) anti-clockwise until it is fully open.
m
atio
om
– Screw adapter - V.A.G 1318/20–1- onto the adapter - V.A.G
n in
or c
1318/20- .
thi
te
sd
iva
– Screw adaptor - V.A.G 1318/20- onto the bleed valve hand-
o
r
rp
cu
o
tight.
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.
– Connect the hose from diesel extractor - VAS 5226- as shown.

– Screw valve (on the T-piece) into bleed valve clockwise up to
the stop.
– Check adapters and hose connections for leaks.
Note
The fuel pump is activated via the final control diagnosis.

– Connect diagnosis cable connector to diagnostic connection
in driver footwell.
– Select Final control diagnosis in Engine electron-
ics .
– Press right arrow button ► on the display to initiate actuation

of fuel pump.
– End final control diagnosis when fuel flows from bleed valve
free of air bubbles.
1. Injection system 141

Caddy 2011 ➤
– Turn valve (on the T-piece) anti-clockwise until it is fully open

again.
– Clamp off hose from diesel extractor - VAS 5226- (e.g. with
hose clamps, up to 25 mm in diameter - 3094- ) and pull it off
adapter - V.A.G 1318/20–1- .
– Unscrew adapter - V.A.G 1318/20- from the bleed valve.
lkswage es n
o ot g
byV ua
d ran
ir se tee
ho
– Screw cover cap -arrow- onto bleed valve again. aut or
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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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.

lkswage es n
o ot g
byV ua Caddy 2011 ➤
d ran
ir se
tho 4-cylinder injection tee
oengine (1.6 l engine, BiFuel) - Edition 12.2015
au ra
ss c
ce
le
un
2 Injectors
pt
an
d
itte
y li
erm
ab
⇒ “2.1 Assembly overview - fuel rail with injectors”, page 143
ility
ot p
wit
⇒ “2.2 Removing and installing injectors”, page 143
is n
h re
ole,
⇒ “2.3 Checking injectors for leaks and quantity injected”,
spec
page 144
t to the co
⇒ “2.3.1 Checking for leaks”, page 145
⇒ “2.3.2 Checking quantity injected”, page 147
rrectne
2.1 Assembly overview - fuel rail with injectors
ss o
cial p
f in
1 - Fuel rail
form
mer
2 - Injector, cylinder 1 - N30- to
atio
m
injector, cylinder 4 - N33-

o
n
c
i
or
n thi
te
sd
a
⇒ page 143 .
iv
o
pr
cum
r
fo
3 - O-ring
en
ng
t.
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❑ Renew after removing Cop py
t. rig
gh
❑ Lubricate with clean en‐
ht
pyri by
Vo
o
gine oil.
c by lksw
cted agen
Prote AG.
4 - Retaining clip
❑ Ensure correct seating
on injector and fuel rail.
5 - Protective cap
6 - Breather valve
7 - Bolt
❑ 8 Nm
2.2 Removing and installing injectors

Removing
– Remove intake manifold lower part ⇒ page 149
2. Injectors 143
Caddy 2011 ➤ agen
AG. Volkswagen AG d
oes
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4-cylinder injection engine (1.6 l engine, BiFuel)
by V - Edition 12.2015
ol
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ed ran
oris tee
th or
au ac
WARNING ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
connection.
hole
spec
es, in part or in w
t to the co
– Remove fuel line -2- and catch escaping fuel with a cleaning
cloth.
rrectness of i
Note
l purpos
nform
mercia
– Pull off plug connectors on all injectors.
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi
– Pull off retainer clip -arrow- and remove injector.
Co
Cop py
t. rig
Installing
gh ht
pyri by
Vo
co lksw
by
Installation is carried out in the reverse order; note the following: cted agen
Prote AG.
– Renew the O-rings at all opened connections. (Under no cir‐

cumstances may the plastic cap be pulled off the valve head
in order to renew front O-ring on injector.)
– Lubricate the O-rings lightly with clean engine oil.
– Ensure that the injectors are installed in the correct position.
– Make sure retaining clips are properly connected.

– Position fuel rail together with secured injectors against intake
manifold and press into place evenly.
– Install lower part of intake manifold ⇒ page 149 .
2.3 Checking injectors for leaks and quantity injected

Caddy 2011 ➤

equipment required
♦ Remote control for V.A.G
1348 - V.A.G 1348/3A-
♦ Adapter cable - V.A.G
1348/3-2-
♦ Injection rate tester - V.A.G
1602-
♦ Auxiliary measuring set -
V.A.G 1594C-
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
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
nform
mercia
at
om
ion
Note
c
in t
or
his
ate
do
riv
♦ Always follow the safety precautions. ⇒ page 5

p
cum
for
♦ Observe rules for cleanliness. ⇒ page 7

en
ng
t.
yi Co
Cop py
t. rig
2.3.1 Checking for leaks
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
WARNING

connection.
Test prerequisite
• The fuel pressure must be OK.
Test procedure
– Remove intake manifold lower part.
2. Injectors 145
Caddy 2011 ➤
– Pull off connector to the injectors.

– Pull fuel rail with injectors off intake manifold and lay on a clean
cloth.
Fuel line remains connected to fuel rail.

lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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
nf
ercia
– Connect right terminal of fuse socket F33 and battery positive

rm
m
(+) with auxiliary cables from auxiliary measuring set - V.A.G

atio
m
1594C- so that fuel pump runs.

o
n in
or c
thi
te
sd
iva
o
r
Note
rp
cu
o
m
f
en
ng
t.
yi
This step serves only to have the fuel pump running when the
Co
Cop py
engine is stopped.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
– Check injectors for leaks (visual check). No more than 1 to 2
agen
Prote AG.
drops per minute must escape from each valve when fuel
pump is running.
If the fuel loss is greater:
– Renew the leaking injector ⇒ page 143 .
Note
♦ If injectors are renewed, erase learnt values and adapt engine

control unit again ⇒ Vehicle diagnostic tester.
♦ Always renew seals.

Caddy 2011 ➤
2.3.2 Checking quantity injected

Test prerequisites
• The fuel pressure must be OK.
• Intake manifold lower part removed.
• Injectors installed in fuel rail and fuel line connected.
Test procedure
– Place the injector which is to be tested into measuring glass
of injection quantity tester - V.A.G 1602- .
AG. Volkswagen AG d
– Pull fuse SB33 out of socket F33 of fuse lholder.
ksw
agen oes
not
Vo gu
by
– Connect right terminal of fuse socket rised F33 and battery positive ara
nte
(+) with auxiliary cables from auxiliary
ut
ho measuring set - V.A.G eo
ra
1594C- so that fuel pump runs.ss a c
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Connect a contact of injector to be tested to engine earth using
test leads from auxiliary measuring set - V.A.G 1594C- .
ss
– Connect second injector contact to remote control - V.A.G
o
cial p
f
1348/3A- using adapter cable - V.A.G 1348/3-2- .
inform
mer
– Connect crocodile clip to battery (+).
atio
om
n
– Operate remote control - V.A.G 1348/3A- for 30 seconds.
c
i
or
n thi
te
– Repeat check on other injectors. Use new measuring beakers.

sd
iva
o
pr
cum
r
– After all injectors have been activated, place measuring beak‐

fo
en
ng
ers on a level surface and compare the quantity injected.

t.
yi Co
op
Specification: 85…105 ml per injector C py
t. rig
gh ht
yri by
When checking the quantity injected, check the spray pattern as op Vo
by c lksw
well. The spray patterns must be the same for all injectors. cted agen
Prote AG.
If the measured values of one or more injectors are above or be‐

low the prescribed specifications:
– Renew defective injector ⇒ page 143 .
Note
If injectors are renewed, erase learnt values and adapt engine

control unit again ⇒ Vehicle diagnostic tester.
2. Injectors 147
Caddy 2011 ➤
3 Intake manifold
⇒ “3.1 Assembly overview - intake manifold”, page 148
⇒ “3.2 Removing and installing lower part of intake manifold”,
page 149
⇒ “3.3 Removing and installing intake manifold”, page 151
⇒ “3.4 Checking intake manifold change-over”, page 156
⇒ “3.4.1 Checking vacuum unit in intake manifold uppergepart
AG.for
Volkswagen AG
a n does
leaks”, page 158 Volksw not
g y ua
db ran
3.1 Assembly overview - intake manifold tho
rise tee
or
au ac
ss
ce
le
un
1 - Intake manifold pressure
pt
an
d
sender - G71- with intake air

itte
y li
rm
temperature sender - G42- .
ab
pe
ility
ot
2 - Bolt
wit
, is n
h re
❑ 3 Nm
hole
spec
3 - O-ring
es, in part or in w
t to the co
4 - Upper part of intake mani‐
rrectness of i
fold
❑ With intake manifold
l purpos
change-over.
5 - Pressure relief valve
nform
ercia
❑ protects the intake

m
a
com
t
manifold from damage
ion in
at overpressure.
r
te o
thi
s
iva
6 - Seal do
r
rp
cum
fo
en
ng
t.
yi Co
7 - Throttle valve module - Cop py
J338-
t. rig
gh ht
pyri by
❑ Including throttle valve
o Vo
by c lksw
cted
drive (electric throttle
agen
Prote AG.
operation) - G186- , an‐
gle sender 1 for throttle
valve drive (electric
throttle operation) -
G187- and angle sender
2 for throttle valve drive
(electric throttle opera‐
tion) - G188- .
8 - Bolt
❑ 8 Nm
9 - Bolt
❑ 15 Nm
10 - Rubber bush
11 - Bolt
❑ 8 Nm

Caddy 2011 ➤
12 - Support
13 - Spreader rivet
14 - Seal
15 - Intake manifold lower part
16 - Seal
17 - Washer
18 - Bolt
❑ 25 Nm
19 - Nut
❑ 25 Nm
20 - Bolt
❑ 8 Nm +180°
21 - Gas rail AG. Volkswagen AG d
agen oes
22 - Bolt olksw not
byV gu
ara
d
❑ 5 Nm orise nte
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h
ut ra
23 - Bolt ss a c
ce
le
❑ 3 Nm
un
pt
an
d
itte
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24 - Vacuum hose
erm
ab
❑ To vacuum positioning element
ility
ot p
wit
is n
25 - Variable intake manifold changeover valve - N156-
h re
ole,
spec
26 - Vacuum hose
t to the co
❑ To vacuum reservoir in intake manifold.
rrectne
3.2 Removing and installing lower part of in‐
take manifold
ss o
cial p
f i
nform
mer

atio
om
n
c
i
or
n thi
te
sd
iva
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.
3. Intake manifold 149

Caddy 2011 ➤
Note
AG. Volkswagen AG d
agen oes
ksw
♦ Always follow safety precautions ⇒ page 5 . by Vol not
gu
ara
d
ise nte
♦ Observe rules for cleanliness ⇒ page 7 . thor eo
au ra
♦ The fuel line remains connected. ss c
ce
le
un
pt
an
d
itte
Removing
y li
erm
ab
ility
– Pull connector -1- off the secondary air pump motor.
ot p
wit
is n
– Remove pressure hoses -2- and -3- on the secondary air pump
h re
ole,
motor.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
– Release clip -1- and detach hose.

o
n
c
i
or
n thi
e
– Disconnect connector -3-, and unscrew bolts -2-.

t
sd
iva
o
pr
c
– Unbolt secondary air pump motor.
um
r
fo
en
ng
t.
yi
– Pull out oil dipstick with funnel from the guide tube and from
Co
op py
the bracket for the secondary air pump. t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew bolts -1- and -2- and the nuts -3- of the bracket for
the secondary air pump.
– Relax poly V-belt and unplug tensioning element, using lock‐
ing pin - T10060 A- .

Caddy 2011 ➤
– Remove deflector plate -arrows-.
– Remove both expansion rivets -1-.

– Unscrew the two bolts -2-.
– Undo all the remaining bolts -3- from the lower part of the in‐
take manifold to the cylinder head.
– Unscrew bolts -4- from the fuel rail.
– Undo the spreader rivits of the cable guide on the fuel rail.
wage
e ks s no
Vol t gu
– Carefully push apart the two tabs on the upper epartd b of the in‐
y ara
take manifold and withdraw the lower part of tho
the intake mani‐
ris nte
eo
fold downwards. While doing so, release fuel
s au rail with injectors ra
c
from lower part of intake manifold. s
ce
le
un
pt
an
d
itte
– Withdraw the fuel rail with the injectors from the lower part of
y li
erm
ab
the intake manifold simultaneously -arrow- and lay them down
ility
ot p
on a clean cloth in the engine compartment.
wit
is n
h re
Installing
ole,
spec
t to the co
– Renew seals between intake manifold and cylinder head.
– Renew seals between injector and intake manifold and mois‐
rrectne
ten slightly with clean engine oil.
– Position fuel rail together with injectors against intake manifold
ss
and press into place evenly.
o
cial p
f inform
– Make sure the seal between the lower part and the upper part
mer
of the intake manifold is seated properly.

atio
om
n
c
i
or
n thi
e
Note
t
sd
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Secure all hose connections with hose clips which conform to the
en
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t.
production standard.
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Specified torques op Vo
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Prote
AG.
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 143
3.3 Removing and installing intake manifold


Caddy 2011 ➤
♦ Hose clamps up to 25 mm - 3094-
AG. Volkswagen AG d
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The upper part of the intake manifold is removed and installed s
ce
le
together with the lower part of the intake manifold.

un
pt
an
d
itte
y li
erm
ab
Removing
ility
ot p
wit
– Remove intake hose between the throttle valve module - J338-

is n
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and the air filter.

ole,
spec
– Pull off the vacuum hose -arrow- to the brake servo unit at the
t to the co
intake manifold.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
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t.
yi Co
Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Pull off hoses -2- and -3- on the secondary air pump.
– Unscrew the secondary air pump -4- from the bracket.
lkswage es n
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d ran
ir se tee
tho
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a ac
ss
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Unscrew bolts -arrows-, and fold down gas rail.
wit
, is n
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
– Unscrew bolts -1- and -2-, and remove bracket.
or
his
ate
– Pull out oil dipstick with funnel from the guide tube and from
do
priv
c
the holder for the secondary air pump.
um
for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
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cted agen
Prote AG.
– Unscrew bolts -1- and -2- and the nuts -3- of the bracket for
the secondary air pump.
– Relax poly V-belt and unplug tensioning element, using lock‐
ing pin - T10060 A- .

Caddy 2011 ➤
– Remove deflector plate -arrows-.

– Unscrew bolts from the fuel rail.
wage es n
Fuel line remains connected to fuel rail. yV
olks ot g
ua
b
ed ran
– Undo the spreader rivits of the cable guide on the fuel hrail.
oris tee
ut or
a ac
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
– Disconnect vacuum line -1- for the activated charcoal filter
es, in part or in w
solenoid valve 1 - N80- and unclip it at the intake manifold.
t to the co
– Disconnect all electrical plug connectors on the intake mani‐
fold.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
– Clamp off coolant hose to heat exchanger for heater using
um
fo
en
g
hose clamps, up to 25 mm in diameter - 3094- .

n
t.
yi Co
Cop py
– Pull coolant hoses -1- and -2- off at the throttle valve housing.
t. rig
gh ht
pyri by
Vo
o
– Lay open the coolant hose to the expansion tank on the intake
c by lksw
cted agen
manifold. Prote AG.
– Disconnect electrical connector -3- at throttle valve module -

J338- .
– Remove bolts -1- and -2-.

Caddy 2011 ➤
– Remove throttle valve module - J338- -arrows-.
– Remove one bolt each -arrow- on left and right sides of rear
intake manifold mounting.
– Unscrew hose clamp -2-.

AG. Volkswagen AG d
agen
– Loosen union nut -1-. Volksw
oes
not
gu
by ara
d
– Unscrew nuts -3- and remove the connection
orise pipe for the ex‐ nte
eo
haust gas recirculation. auth
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
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hole
spec
– Remove bolts -1- to -8- and remove intake manifold.

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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rp
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fo
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Withdraw the fuel rail with the injectors from the lower part of
the intake manifold simultaneously -arrow- and lay them down
on a clean cloth in the engine compartment.
Note
Block off intake ports in cylinder head with clean cloths.
Installing
– Renew seals between intake manifold and cylinder head.
– Renew seals between injector and intake manifold and mois‐
ten slightly with clean engine oil.
– Position fuel rail together with injectors against intake manifold
and press into place evenly.
– Check coolant level.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Note orise nte
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h
aut ra
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Secure all hose connections with hose clips which conform to the s
ce
le
production standard.
un
pt
an
d
itte
y li
erm
ab
Specified torques
ility
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wit
is n
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ole,
♦ ⇒ “2.1 Assembly overview - fuel rail with injectors”, page 143
spec
t to the co
Bracket for gas rail on intake 20 Nm
manifold M8×35 rrectne
Bracket for gas rail on intake 6 Nm
manifold M6×16
ss o
Deflector plate to ancillary 23 Nm

cial p
f in
bracket
form
mer
Secondary air pump bracket to 20 Nm

atio
m
intake manifold
o
n
c
i
or
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sd
a
3.4 Checking intake manifold change-over

iv
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Only carry out this test if torque is insufficient, i.e. if elasticity or

t.
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op
pulling power is inadequate. C py
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♦ Hand vacuum pump with accessories - V.A.G 1390-
Prote AG.

Caddy 2011 ➤
♦ Vacuum tester - V.A.G 1368-
AG. Volkswagen AG d
agen oes
olksw not
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ara
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un
pt
Test prerequisite
an
d
itte
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• The variable intake manifold changeover valve - N156- has erm
ab
ility
been checked with ⇒ Vehicle diagnostic tester.
ot p
wit
is n
If the variable intake manifold changeover valve - N156- is OK,
h re
ole,
perform the following tests:
spec
– Check that vacuum lines are connected correctly.
t to the co
– Check vacuum hoses for porosity.
rrectne
– Check vacuum system for leaks.
– Checking vacuum unit in upper part of intake manifold for leaks
ss
⇒ page 158 .
o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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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.

Caddy 2011 ➤
3.4.1 Checking vacuum unit in intake manifold

upper part for leaks
– Pull vacuum hose to actuator for intake manifold changeover
-arrow- off at the intake manifold changeover valve -1-.
Note
The actuator for the variable intake manifold change-over valve

is integrated in the intake manifold and is not therefore visible from
the outside.
– Connect hand vacuum pump with accessories - V.A.G 1390-

to vacuum tester - V.A.G 1368-nconnection
AG. VolkswageB.
nA ge G do
swa es
– Connect vacuum hose by leading to actuator to vacuum tester
Vol
k not
gu
ara
-
V.A.G 1368- connection
ir se
d A. nte
tho eo
– Set vacuum stester
sa
u
- V.A.G 1368- to -A/B- position. ra
c
ce
e
– Operate hand vacuum pump with accessories - V.A.G 1390-

nl
pt
du
an
several times. Build up vacuum to 500 millibars max.
itte
y li
erm
ab
– Vacuum must not drop.
ility
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wit
If vacuum drops:
, is n
h re
hole
– Renew upper part of intake manifold ⇒ page 151 .

spec
es, in part or in w
If pressure does not drop: t to the co
– Check switchover mechanism in the intake manifold for ease

of movement.
rrectness of i
– Remove intake manifold lower part.

l purpos
– Repeat leak test on the vacuum actuator. Check whether in‐

take manifold flap moves.
nf
ercia
or
If a fault is found:
m
m
atio
om
– Renew upper part of intake manifold.

n in
or c
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te
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Cop py
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Prote AG.

Caddy 2011 ➤
4 Air filter
⇒ “4.1 Assembly overview - air filter housing”, page 159
4.1 Assembly overview - air filter housing
1 - Bolt
❑ 5 Nm
2 - Air duct channel
3 - Air funnel
4 - Slider
5 - Bolt
AG. Volkswagen AG d
❑ 2 Nm ksw
agen oes
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6 - Intake hose ise d b ara
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or
❑ With acrankcase
ut
h breath‐ eo
ra
er valve.
ss c
ce
le
un
pt
7 - Connection for crankcase
an
d
itte
breather
y li
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ab
❑ With heater element for
ility
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cold climates.
wit
is n
h re
ole,
8 - Air duct
spec
9 - Bolt
t to the co
❑ 2 Nm
10 - Bolt
rrectne
❑ 8 Nm
s
11 - Bolt
s o
cial p
❑ 3 Nm
inform
mer
12 - Air filter upper part

atio
om
13 - Filter element
n
c
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14 - Air filter housing

t
sd
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15 - Damping chamber
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16 - Nut
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Cop py
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❑ 20 Nm
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17 - Spring-type clip Prote
cted AG.
agen
18 - Intake air duct

19 - Bolt
❑ 2 Nm
20 - Snap-lock nut
4. Air filter 159

Caddy 2011 ➤
5 Senders and sensors

⇒ “5.1 Checking fuel pressure regulator and holding pressure”,
page 160
5.1 Checking fuel pressure regulator and holding pressure

equipment required AG. Volkswagen AG d
agen oes
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♦ Pressure gauge - V.A.G ed b ara
nte
is
1318- hor eo
aut ra
c
♦ Adapter - V.A.G 1318/9- ss
ce
e
nl
pt
du
♦ Adapter set - V.A.G
an
itte
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1318/17-
erm
ab
ility
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♦ Connector - V.A.G
wit
1318/23-
, is n
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hole
♦ Remote control for V.A.G
spec
1348 - V.A.G 1348/3A-
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
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sd
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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.
Note
♦ The fuel pressure regulator regulates the fuel pressure to ap‐

prox. 4 bar.
♦ The fuel pressure regulator is located on the fuel filter.
♦ Always follow the safety precautions . ⇒ page 5
♦ Observe rules for cleanliness. ⇒ page 7

AG. Volkswagen AG d
agen oes Caddy 2011 ➤
olksw not
yV gu
ed 4-cylinder injection engine (1.6 l engine,
b ara BiFuel) - Edition 12.2015
ris nte
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WARNING
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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connection.
hole
spec
es, in part or in w
t to the co
– Separate fuel supply pipe assembly -1- and catch escaping
fuel with a cloth.
rrectness of i
l purpos
Note
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
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m
f
en
ng
t.
yi Co
op
– Connect pressure tester - V.A.G 1318- with the adapter set - C py
ht. rig
V.A.G 1318/17- to the fuel filter -1- and to the supply line -2-. rig ht
py by
co Vo
by lksw
– Open shut-off tap of pressure tester - V.A.G 1318- . The handle cted agen
Prote AG.
points in direction of flow.
– Measure fuel pressure. Specification: approx. 4.0 bar.
If the specification is not reached:
– Checking fuel pump delivery rate ⇒ page 134
– If fuel pump is OK., renew fuel pressure regulator
⇒ Item 5 (page 105) .
If specification is reached:
– Check for leaks and check the holding pressure (entire sys‐
tem) by observing the pressure drop on the gauge. After 10
minutes, there must be a residual pressure of at least 3.0 bar.
If the holding pressure drops below 3 bar:
5. Senders and sensors 161

Caddy 2011 ➤
swage es n
– After pressure has built up, switch boff y V the ignition. At the same
o lk ot g
ua
time, close pressure tester - V.A.G ir se 1318- shut-off tap (handle
d ran
tee
at right angles to direction ofuthflow -arrow-).
o
or
a ac
ss
– Observe pressure drop (at engine end) on pressure gauge.
ce
le
un
pt
an
If the pressure drops again:
d
itte
y li
rm
ab
– Check line connections, O-rings on fuel rail and injectors for
pe
ility
leaks ⇒ page 144 .
ot
wit
, is n
h re
– Check pressure tester - V.A.G 1318- for leaks.
hole
spec
es, in part or in w
t to the co
Note
Before removing pressure tester - V.A.G 1318- , place a cloth
rrectness of i
around the connections to be undone.
l purpos
If the pressure does not drop:
nform
ercia
– Check connections of lines leading to fuel tank and check the

non-return valve of fuel pump ⇒ page 138 .
m
a
com
tion in
– If non-return valve is OK., renew fuel pressure regulator
r
te o
thi
⇒ Item 5 (page 105) .
s
iva
do
r

rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
6 Engine control unit

⇒ “6.1 Removing and installing engine control unit J623 and gas
mode control unit J659 ”, page 163
⇒ “6.2 Removing and installing anti-theft engine control unit J623
and gas mode control unit J659 ”, page 164
6.1 Removing agen

AG.and
Volkswinstalling
agen AG
does engine control
ksw
d unit - J623- and gas mode gucontrol unit -
ol not
V
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J659-
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ss
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nl
pt
du
Note
an
itte
y li
erm
ab
If the engine control unit needs to be renewed, connect the ⇒ Ve‐
ility
ot p
hicle diagnostic tester, and carry out function Renew engine
wit
, is n
control unit .
h re
hole
spec
es, in part or in w
Removing
t to the co
rrectness of i
l purpos
– Loosen securing nuts -arrows-.

nf
ercia
– Release connector from engine control unit and pull off.

orm
m
atio
om
n in
or c
thi
te
sd
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f
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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.
– Push off retaining plate -1- off engine control unit in direction
of arrow.
Installing
– Push retaining plate onto engine control unit.
6. Engine control unit 163

Caddy 2011 ➤
– Tighten securing nuts -arrows-.

– Attach and lock connectors.
– Install plenum chamber bulkhead ⇒ General body repairs, AG. Volkswagen AG d
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . agen oes
ol ksw not
V y gu
db ara
Specified torque rise nte
tho eo
au ra
ss c
ce
le
un
Control unit retainer 10 Nm
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
6.2 Removing and installing anti-theft en‐
spec
gine control unit - J623- and gas mode
t to the co
control unit - J659-
rrectne
♦ Grip pliers
ss o
cial p
f in
Note
form
mer
atio
m
If the engine control unit needs to be renewed, connect the ⇒ Ve‐

o
n
c
i
hicle diagnostic tester, and carry out function Renew engine
or
n thi
e
control unit .
t
sd
iva
o
pr
cum
r
fo
en
ng
Removing: yi
t.
Co
op py
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
exterior; Rep. gr. 50 ; Body - front; Plenum chamber bulkhead . Prote AG.
Note
The shear-head bolt threads are coated with locking compound.

To simplify removing, the shear-head bolts can be heated using
hot air blower - VAS 1978/14- . When doing this, ensure that no
adjacent cables, connectors or components are damaged!
– Unscrew shear-head bolts -arrows- using a pair of pliers and

remove cover of protective housing.
– Loosen securing nuts -arrows- of control unit bracket.

Caddy 2011 ➤
– Release and pull off plug from engine control unit - J623- and
gas mode control unit - J659- .
– Press catches -1- and -2- outwards. Pull engine control unit
off control unit bracket in direction of arrow.
Installing
– Push engine control unit - J623- and gas mode control unit -
J659- onto the control unitgebracket
n AG. Volkuntil
swageitn locks
AG d into place.
wa oes
olks no
– Connect and lock db
yplug
V on engine control unit - J623-
t gu and gas
ara
mode controlorunit
ise - J659- . nte
e th or
s au ac
s
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
– Fit rubber element -1- onto the control unit bracket

wit
, is n
-in the direction of the arrow-.

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
c
– Insert control unit holder into support -arrow-.

or
thi
te
sd
iva
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rp
cu
o
m
f
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.
6. Engine control unit 165

Caddy 2011 ➤
– Tighten securing bolts -arrows-.

– Fit cover of protective housing.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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h
aut ra
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
– Tighten shear-head bolts -arrows- evenly until heads shear
spec
off.
t to the co
– Install plenum chamber bulkhead ⇒ General body repairs,
rrectne
Specified torque
ss o
cial p
f
Control unit retainer 10 Nm
inform
mer
atio
om
n
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
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 167
⇒ “1.2 Separating exhaust pipes, silencers”, page 168
⇒ “1.3 Installation position of clamps”, page 169
⇒ “1.4 Checking exhaust system for leaks”, page 169
1.1 Assembly overview - silencers
1 - Centre silencer
❑ Combined in one unit
with rear silencer as
original equipment. Can
be renewed separately
for repair purposes
❑ Separate exhaust sys‐
tem ⇒ page 168
2 - Rubber mounting
3 - Bolt
❑ 25 Nm lkswage es n
o ot g
byV ua
4 - Separating point ir se
d ran
tee
ho
❑ Separate exhaust sys‐ aut or
ac
tem ⇒ page 168 ss
ce
e
nl
pt
du
5 - Rear silencer
an
itte
y li
❑ In initial equipment,
erm
ab
ility
component with centre
ot p
silencer. Can be re‐ wit

, is n
h re
newed individually for
hole
repair purposes.
spec
es, in part or in w
❑ Separate exhaust sys‐

t to the co
tem ⇒ page 168

6 - Nut
rrectness of i
❑ 23 Nm
l purpos
7 - Tunnel cross-piece
nform
mercia
at
om
ion
c
in t
or
his
ate
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.
1. Exhaust pipes, silencers 167

Caddy 2011 ➤
1.2 Separating exhaust pipes, silencers
Note
♦ Renew seals, gaskets and self-locking nuts.

♦ 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 clamp and align silencers and
exhaust pipe so that sufficient clearance is maintained to the
bodywork at all points and the mountings are evenly loaded.
♦ The connecting pipe can be cut through at the point marked

in order to renew the centre and rear silencers separately.
♦ Cutting location is marked by an indentation on the circumfer‐
ence of exhaust pipe.
♦ Pneumatic sabre saw - V.A.G 1523 A-
AG. Volkswagen AG d
♦ or chain pipe cutter - VAS 6254- agen oes
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ara
ed
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nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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hole
spec
es, in part or in w
t to the co
♦ Eye protection
rrectness of i
l purpos
WARNING
nf
ercia
To avoid injury from metal shavings, wear eye protection and

or
protective clothing.
m
m
atio
om
n in
or c
thi
te
sd
iva
o
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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.
168 Rep. gr.26 - Exhaust system

Caddy 2011 ➤
– Cut through exhaust pipe at right angles using e.g. body saw
- V.A.G 1523 A- at separating point -arrow 2-.
– Position clamping sleeve at the side marks -arrow 1- and
AG. Volkswagen AG d
-arrow 3- when fitting. kswagen oes
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– Install clamp so that bolt ends do not protrude beyond the low‐
spec
er edge of the clamp -arrow-.
t to the co
Bolt connections point to the right.
rrectness o
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1.3 Installation position of clamps
pr
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Installation position of clamp
Co
Cop py
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– Install clamp so that bolt ends do not protrude beyond lower
gh ht
pyri by
edge of clamp -arrow-.
o Vo
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Prote AG.
Bolt connections point to the right.
1.4 Checking exhaust system for leaks

– Plug tailpipes (e.g. with cloths or sealing plugs) and leave
plugged until leak test is complete.
– Listen for noise at connection points (cylinder head/exhaust
manifold, exhaust manifold/front exhaust pipe, etc.) to locate
any leaks.
– Rectify any leaks that are found.
1. Exhaust pipes, silencers 169

Caddy 2011 ➤
2 Emission control
⇒ “2.1 Assembly overview - emission control”, page 170
⇒ “2.2 Removing and installing catalytic converter”, page 171
2.1 Assembly overview - emission control
1 - Exhaust manifold
⇒ page 178 .
2 - Nut
❑ 25 Nm
3 - Lambda probe - G39-
❑ Before catalytic convert‐ agen
AG. Volkswagen AG d
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❑ Grease only othread
ris
e with nte
high-temperature
aut
h eo
ra
paste . The
ss high-tem‐ c
perature paste ⇒ Elec‐
ce
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nl
pt
du
tronic Parts Catalogue

an
itte
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(ETKA) must not get into
erm
ab
the slots on the probe
ility
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body.
wit
, is n
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❑ 55 Nm
hole
spec
4 - Clamp
es, in part or in w
t to the co
❑ Installation position
⇒ page 169 .
❑ Tighten bolted connec‐
rrectness of i
tions evenly.
l purpos
5 - Nut
❑ 25 Nm
nf
ercia
or
6 - Tunnel cross-piece
m
m
atio
m
7 - Nut
o
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or c
thi
❑ 23 Nm
te
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8 - Lambda probe after catalyt‐

rp
cu
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ic converter - G130-
f
en
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t.
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❑ Grease only thread with Cop py
t. rig
high-temperature yri
gh by
ht
paste . The high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) must not get into the slots on
op Vo
by c lksw
the probe body.
cted agen
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❑ The connector is located beneath right underbody panel.
❑ 55 Nm
9 - Bolt
❑ 25 Nm
10 - Mounting
11 - Front exhaust pipe
❑ With catalytic converter.
❑ Protect from damage by knocks and impact.
❑ With decoupling element.
❑ Do not bend decoupling element more than 10° - otherwise it may be damaged.

AG. Volkswagen AG d
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agen oes
not
Caddy 2011 ➤
ol
4-cylinder injection
d byV engine (1.6 l engine, BiFuel) gu- Edition 12.2015
aran
ise tee
or
❑ Removing and installing ⇒ page 171 au .
th or
ac
ss
12 - Nut
ce
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nl
pt
du
an
itte
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erm
❑ Coat exhaust manifold studs with high-temperature paste ⇒ Electronic Parts Catalogue (ETKA) .
ab
ility
ot p
❑ Observe tightening sequence ⇒ page 171 .
wit
, is n
h re
❑ 25 Nm
hole
spec
13 - Gasket
es, in part or in w
t to the co
rrectness of i
2.2 Removing and installing catalytic con‐
l purpos
verter
nform
ercia
Removing
m
at
om
ion
c
Note
in t
or
his
ate
do
riv
♦ Renew seals, gaskets and self-locking nuts.

p
cum
for
en
♦ After working on the exhaust system, ensure that the system
ng
t.
yi Co
is not under stress and that there is sufficient clearance to the Cop py
bodywork. If necessary, loosen clamp and align silencers and
ht. rig
rig ht
by
exhaust pipe so that sufficient clearance is maintained to the copy Vo
by lksw
bodywork at all points and the mountings are evenly loaded. cted agen
Prote AG.

– Disconnect the electrical plug connection for Lambda probe
after the catalytic converter - G130- .
– Remove cross member for underbody -arrows-.
Note
The flexible joint in front exhaust pipe must not be bent more than
10° - risk of damage.
– Disconnect exhaust system at clamping sleeve -1-.
– Unbolt bracket for exhaust system -arrows-.
2. Emission control 171

AG. Volkswagen AG d
agen oes
olksw not
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Caddy 2011 ➤ d by ara
ise nte
r
4-cylinder injection engine (1.6 lutengine, BiFuel) - Edition 12.2015
ho eo
ra
s a c
s
– Remove heat shield for drive shaft on right side -arrows-.
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
– Unscrew securing nuts -arrows- for front exhaust pipe to ex‐
nform
ercia
haust manifold.
m
a
– Detach front exhaust pipe with catalytic converter.
com
tion in
Installing
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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op
Note C py
t. rig
gh ht
pyri by
Vo
o
Renew seals, gaskets and self-locking nuts. by c lksw
cted agen
Prote AG.
– Tighten the exhaust pipe in the tightening sequence shown on

the exhaust manifold.
Specified torques

Caddy 2011 ➤
3 Exhaust gas recirculation

⇒ “3.1 Assembly overview - exhaust gas recirculation”,
page 173
3.1 Assembly overview - exhaust gas recir‐

culation
Note
All components are mounted on all engines regardless of emis‐

sions standard (e.g. mechanical exhaust gas recirculation valve).
However, these are not always used and actuated. With exhaust
gas PR number 0GV (emissions standard EU2), the mechanical
exhaust gas recirculation valve cannot be adapted because the
function is not enabled in the software. The production control
numbers are located on the vehicle data sticker.
1 - Gasket
2 - Bolt
❑ 10 Nm
3 - Connecting pipe
4 - Exhaust manifold
AG. Volkswagen AG d
agen
5 - Bolt olksw
oes
not
byV gu
ara
❑ 4 Nm rised
nte
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ut
6 - Retaining clamp ss a ra
c
❑ for line Lambda probe
ce
e
nl
pt
du
before catalytic convert‐

an
itte
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er
erm
ab
ility
ot p
7 - Connection
wit
, is n
❑ 80 Nm
h re
hole
spec
8 - Lambda probe - G39-

es, in part or in w
t to the co
❑ 55 Nm
9 - Connector
rrectness of i
❑ 6-pin
l purpos
10 - Connection
❑ 60 Nm
nf
ercia
11 - Throttle valve module -

orm
J338-
m
atio
om
n in
12 - Nut
or c
thi
e
❑ 25 Nm
t
sd
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rp
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13 - Exhaust gas recirculation

o
m
f
en
ng
valve - N18- with exhaust gas

t.
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recirculation potentiometer - . Cop py
G212-
ht rig
rig ht
py by
Vo
❑ If renewed, erase learnt
co lksw
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cted agen
values and readapt engine control unit ⇒ Vehicle diagnostic tester. Prote AG.
14 - Connector
❑ 6-pin
3. Exhaust gas recirculation 173

Caddy 2011 ➤
AG. Volkswagen AG d
15 - From air filter agen oes
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16 - Breather hose rised
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17 - Connection with combination valve ss a ra
c
❑ Bracket for exhaust gas recirculation valve - N18-
ce
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un
pt
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ab
pe
ility
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spec
es, in part or in w
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com
tion in
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thi
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
4 Secondary air system

⇒ “4.1 Function”, page 175
⇒ “4.2 Assembly overview - secondary air system”, page 175
⇒ “4.3 Checking combination valve”, page 176
4.1 Function
During a cold start, air is temporarily blown from the secondary
air system into the exhaust ports. This produces an oxygen rich
exhaust gas, causing afterburning and reducing the heat-up
phase of the catalytic converter.
n AG. Volkswagen A
4.2 Assembly overview Volks - secondary air sys‐
wage
G do
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tem by ua
ed ran
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c
ss
Caution
ce
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un
pt
an
d
itte
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rm
ab
pe
ility
tions:
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
out.
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.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Secondary air system 175

Caddy 2011 ➤
1 - Combination valve
2 - Bolt
❑ 10 Nm
3 - O-ring
4 - Pressure hose
❑ Check for secure seat‐
ing.
❑ Press together at front
to release.
5 - Intake hose
❑ For secondary air pump. wage
es n
olks ot g
6 - To air filter byV ua
d ran
ir se tee
o
7 - Secondary air pump motor auth or
ac
- V101- ss
ce
le
un
pt
8 - Connector
an
d
itte
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❑ 2-pin
erm
ab
ility
ot p
9 - Nut
wit
is n
❑ 10 Nm
h re
ole,
spec
10 - Bolt/nut
t to the co
❑ 25 Nm
11 - Bolt
rrectne
❑ 8 Nm
12 - Bracket
ss o
❑ For secondary air pump
cial p
f i
motor - V101-
nform
mer
❑ Secured to intake mani‐
atio
m
fold.
o
n
c
i
or
13 - Intake manifold lower part n thi

te
sd
iva
14 - Bolt
pr
cum
r
fo
❑ 10 Nm
en
ng
t.
yi Co
op py
15 - Gasket t. C rig
gh ht
yri by
❑ Renew after removing cop Vo
by lksw
cted agen
❑ Note installation position. Prote AG.
16 - Connection
❑ For combination valve
4.3 Checking combination valve

• Hose connections must be leak-free.
Note
Do not use compressed air during the following check!

Caddy 2011 ➤
– Remove pressure hose -arrow- on the secondary air pump

motor - V101- .
Note
To release, press buttons on hose coupling together.
– Blow with light pressure into the pressure hose to the combi‐
lkswagen AG
nation valve. Combination valve AG. Vobe
genmust closed. does
sw a
olk not
yV g
– Blow with strong pressure
ise
db into the pressure hose to the com‐
ua
ran
bination valve. Combination
thor valve must open. tee
o
au ra
c
ss valve does not open, or is constantly open:
If the combination
ce
e
nl
pt
du
– Renew combination valve.
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
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.
4. Secondary air system 177

Caddy 2011 ➤
5 Exhaust manifold
⇒ “5.1 Removing and installing exhaust manifold”, page 178
5.1 Removing and installing exhaust mani‐

fold
Removing
Note
♦ Renew seals, gaskets and self-locking nuts. AG. Volkswagen AG d

agen oes
ksw
♦ After working on the exhaust system, ensurebythat V the system
ol not
gu
is not under stress and that there is sufficient
r is clearance to the
ed ara
nte
bodywork. If necessary, loosen clamp uand th align silencers and
o eo
ra
exhaust pipe so that sufficient clearance
ss a
is maintained to the c
bodywork at all points and the mountings are evenly loaded.
ce
e
nl
pt
du
an
itte
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– Remove front exhaust pipe with catalytic converter
erm
ab
⇒ page 171 .
ility
ot p
wit
, is n
– Removing intake manifold ⇒ page 151 .
h re
hole
spec
– Disconnect and remove electrical plug connection -arrow- for
es, in part or in w
Lambda probe - G39- (from catalytic converter) from the
t to the co
bracket.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
– Unscrew hose clamp -2-.

o
r
rp
cu
o
m
f
– Undo union nut -1-.

en
ng
t.
yi Co
op py
– Unscrew nuts -3- and remove the connection pipe for the ex‐
. C rig
ht ht
rig
haust gas recirculation. py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Remove nuts -1- for heat shield -3- and remove washers -2-.
– Remove nuts -8- for both brackets -4- and remove washers
-7-.
– Remove remaining nuts from exhaust manifold -6- and re‐
move washers.
– Remove exhaust manifold and seal for exhaust manifold -5-.
Installing
Note
Renew seals, gaskets and self-locking nuts.
– Install intake manifold ⇒ page 151 .

– Install front exhaust pipe with catalytic converter
⇒ page 171 .
Specified torques
Exhaust manifold on cylinder 25 Nm
head
Connecting pipe for exhaust 60 Nm
gas recirculation to exhaust
manifold AG. Volkswagen AG d
agen oes
Heat shield on exhaust mani‐ olksw 23 Nm not
V gu
by
fold ised ara
nte
or eo
Connection pipe for exhaust aut
h
23 Nm ra
gas recirculation on the me‐
ss c
ce
le
chanical exhaust gas recircula‐

un
pt
tion valve
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
5. Exhaust manifold 179

Caddy 2011 ➤
28 – Ignition system
1 Ignition system
⇒ “1.1 Assembly overview - ignition system”, page 180
⇒ “1.2 Test data, spark plugs”, page 181
1.1 Assembly overview - ignition system

AG. Volkswagen AG d
1 - Ignition cable agen oes
olksw not
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❑ 4…8 kΩ ed b ara
nte
ris
❑ With suppression con‐ aut
ho eo
ra
nector and spark plug ss c
connector.
ce
le
un
pt
an
d
❑ Check for continuity.

itte
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erm
ab
❑ Pull off spark plug con‐
ility
ot p
nector using puller -
wit
is n
T10112- .
h re
ole,
2 - Ignition transformer - N152-
spec
❑ Markings for H.T. ca‐
t to the co
bles: A = Cylinder 1, B =
Cylinder 2, C = Cylinder
3, D = Cylinder 4
rrectne
3 - Bolt
s
❑ 10 Nm
s o
cial p
f in
4 - Connector
form
mer
❑ 4-pin
atio
m
❑ For ignition transformer

o
n
c
i
or
n
- N152- .
thi
te
sd
va
5 - Spark plug
i
o
pr
cum
r
fo
❑ Type and electrode gap

en
ng
t.
yi
⇒ page 181 .
Co
Cop py
. rig
❑ To remove and install,
ht ht
rig by
py
pull off connectors for co Vo
by lksw
outer injectors.
cted agen
Prote AG.
❑ Remove and install with
spark plug socket and
extension - 3122 B- .
❑ 25 Nm
6 - Connector
❑ 2-pin
❑ For knock sensor 1 - G61- .
7 - Bolt
❑ The specified torque influences the function of the knock sensor.
❑ 20 Nm
8 - Knock sensor 1 - G61-
9 - Bolt
❑ 10 Nm
180 Rep. gr.28 - Ignition system

Caddy 2011 ➤
10 - Hall sender - G40-

AG. Volkswagen AG d
❑ Gold-plated contacts. lksw
agen oes
not
Vo gu
by
11 - Connector rised ara
nte
o eo
❑ For Hall sender - G40-aut .
h
ra
ss c
ce
le
un
pt
an
12 - O-ring d
itte
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erm
ab
ility
ot p
wit
is n
1.2 Test data, spark plugs
h re
ole,
spec
Engine code CHGA
t to the co
Firing order 1-3-4-2
Spark plugs
rrectne
VW/Audi 101,000,033 AA 101 000 041 AC
Electrode gap 0.9 … 1.1 mm 0.9 … 1.1 mm
ss o
Specified torque 25 Nm 25 Nm
cial p
f inform
Change interval ⇒ Maintenance ; Booklet 39
mer
atio
om
n
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
o
by c lksw
cted agen
Prote AG.
1. Ignition system 181

D3E803ECA8A-4-Cylinder Injection Engine (1 6 L Engine BiFuel)

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E803ECA8A

10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1.3 Removing and installing poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.4 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.5 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.2 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.2 Identification of crankshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.4 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2 Bearing shells - installation position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.3 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.4 Checking piston and cylinder bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.5 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.2 Checking oil pressure and oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

20 - Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.1 Emptying fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.3 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

5 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

5.1 Checking fuel pressure regulator and holding pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

6 Engine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

4.3 Checking combination valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

28 - Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

1.1 Engine number, engine data

There is also a sticker on the toothed-belt guard with the “engine

code” and “serial number”.

The engine code is also included on the vehicle data sticker.

Output with LPG kW at rpm 72/5600

Output with petrol kW at rpm 75/5600

Torque with petrol Nm at rpm 148/3800

Bore Diameter, mm 81.0

Compression ratio 10.3

Valves per cylinder 2

Ignition system SIMOS 7.8

2 Safety instructionsn AG. Volkswagen AG

⇒ “2.4 Safety precautions when working on Autogas system”,

Steam may escape when expansion tank is opened. Wear eye

scalding. Cover cap with cloth and open carefully. o

ment, pay attention to the following due to the cramped condi‐

2 Rep. gr.00 - Technical data

♦ When the engine is warm, the cooling system is under pres‐

To prevent injuries to persons and/or damage to the injection and

ignition system, the following must be observed:

♦ Do not touch or disconnect ignition cables when the engine is

running or being turned at starter speed.

♦ Switch off ignition before connecting or disconnecting injection

♦ If the engine is to be turned at starter speed without starting:

Note the following if testers and measuring instruments have to

be used during a road test:

♦ Test and measuring instruments must always be secured to

rear seat and operated by a second person from this location.

If test and measuring instruments are operated from front pas‐

senger seat and the vehicle is involved in an accident, there is a

2.3 Safety precautions during road tests in

♦ Operating from the front passenger seat may result in an ac‐