D3E802E92D9-4-Cylinder Diesel Engine (1 6 L Engine Common Rail)

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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
10 - Removing and installing engine
13 - Crankshaft group
15 - Cylinder head, valve gear
17 - Lubrication
19 - Cooling
21 - Turbocharging/supercharging
23 - Mixture preparation - injection
26 - Exhaust system agen
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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 D3E802E92D9

Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common rail) - Edition 09.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Safety precautions when using testers and measuring instruments during a road test . . . . 3
1.4 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General notes on injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 General notes on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.1 Rules for cleanliness when working on fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Rules for cleanliness when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Rules for cleanliness when working on turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.4 Foreign objects in engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
10 - Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Removing and installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 Removing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2 Separating engine from gearbox . V ............................................ 22
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1.3 Separating engine fromolkdual sw ageclutch gearbox . . .e.s n. o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.4 Securing engine on d engine and gearbox support . . . .ua.ra. . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.5 Installing engine
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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2.2 Removing and installing motor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.3 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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2.4 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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2.5 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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3 Motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
13 - Crankshaft group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.1 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.2 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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1.3 Assembly overview - poly V-belt drive without air conditioner compressor . . . . . . . . . . . . 51
1.4 Assembly overview - poly V-belt drive with air conditioning compressor . . . . . . . . . . . . . . 52
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1.5 Assembly overview - ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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1.6 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

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1.9 Removing and installing poly V-belt without air conditioner compressor . . . . . . . . . . . . . . 61
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1.10 Removing and installing poly V-belt with air conditioner compressor . . . . . . . . . . . . . . . . 61
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1.11 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
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1.12 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.1 Assembly overview - flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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3 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.4 Separating new conrod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.5 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.6 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.7 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . a.g.en. A. G. ..V.o.lk.sw. a. g.e.n .AG . .do. . . . . . . 91
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1.3 Removing and installing cylinder head . . . . . . . . . . . .by. V.o.lk. . . . . . . . . . . . . . . . . . . . .no. t.g.u . 93
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1.4 Removing and installing cylinder head cover . . . .or.is.e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ran109 tee
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1.5 Removing and installing injector seals . . . . . .s a.u. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114or ac
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1.6 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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1.7 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
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2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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2.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
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2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
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3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
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3.2 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3 Measuring axial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
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3.4 Measuring radial play of camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
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3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3.7 Removing and installing valve stem seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
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3.8 Removing and installing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . 151
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

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4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

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17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
1.2 Removing and installing oil sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.4 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
1.5 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 165
1.6 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
2 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
2.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
3 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.1 Assembly overview - oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . 171
3.2 Removing and installing oil filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.4 Checking oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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3.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

4 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.1 Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.2 Removing and installing oil supply line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
1.1 Connection diagram - coolant hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
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1.2 Draining and adding coolant . .lks. w. a.g.en. A. . . . . . . . . . .AG . .do. e.s.n. . . . . . . . . . . . . . . . . . . . . . . . . 187
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1.3 Checking cooling system efor d b leaks . . . . . . . . . . . . . . . . . . . . . u.a.ra. . . . . . . . . . . . . . . . . . . . .
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1.4 Checking engine oil cooler ri for leaks . . . . . . . . . . . . . . . . . . . . . .n.te.e . . . . . . . . . . . . . . . . . .
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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

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2.2 Assembly overview - coolant pump and thermostat, from week 22/2011 . . . . . . . . . . . . . . 197
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2.3 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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2.4 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
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2.5 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 204
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2.6 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 205
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3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
3.2 Removing and installing cowling together with radiator fan V7 and radiator fan on right of
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radiator V35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
3.3 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
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4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
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4.2 Removing and installing lower coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

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4.3 Removing and installing upper coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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4.4 Removing and installing left coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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4.5 Removing and installing right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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1 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
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1.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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226
1.3 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . 231
2 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
2.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
2.3 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
2.4 Removing and installing charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2.5 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
...................................................................... 239
2.6 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
1.3 Assembly overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
1.4 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
1.5 Filling/bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
2.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3 Injectors/high-pressure accumulator (rail) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Contents iii
Caddy 2011 ➤
3.1 Overview - fuel return lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

3.2 Assembly overview - injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.3 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3.4 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
3.5 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
3.6 Adapting correction values for injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
3.7 Replacing O-ring of fuel return lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.8 Check pressure retention valve in fuel return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
3.9 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
3.10 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
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4.3 ris
Pressure testingthohigh-pressure pump . . . . . . . . . . . . . . . . t.ee.o. . . . . . . . . . . . . . . . . . . . . . 295
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5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

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5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

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5.3 Removing and installing throttle valve module J338 with throttle valve potentiometer G69
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........................................................................ 302
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6 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
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6.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
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6.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
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7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
7.1 Removing and installing Lambda probe G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
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8 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
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8.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

8.2 Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . . nform 311
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8.3 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 311
8.4 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
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8.5 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

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8.6 Checking fuel pressure sender G 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

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8.7 Checking fuel metering valve N 290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

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9 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

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9.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 321
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9.2 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 322
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26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
1.2 Separating exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
1.3 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
1.4 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
2.1 Assembly overview - catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
2.2 Assembly overview - particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 342
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.2 Checking changeover for exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . 349
iv Contents
Caddy 2011 ➤
4.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 350

4.4 Checking exhaust gas recirculation cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1.1 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
1.2 Checking glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
1.3 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 356
1.4 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
1.5 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357
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Contents v
Caddy 2011 ➤
AG. Volkswagen AG d
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vi Contents
Caddy 2011 ➤
00 – Technical data
1 Safety
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1.1 Safety precautions when working on the
cooling system
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Hot steam may escape when expansion tank is opened. Wear

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eye protection and protective clothing to avoid eye injuries and

scalding. Cover cap with a cloth and carefully open.
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♦ Route all kinds of lines (e.g. for fuel, hydraulics, activated
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charcoal system, coolant and refrigerant, brake fluid, vac‐
uum) and electrical cables so that the original line routing
is re-established.
♦ To avoid damaging lines, make sure there is sufficient
clearance to all moving or hot components.
1. Safety information 1
Caddy 2011 ➤
Note
♦ Cooling system is pressurized when engine is warm. If nec‐

essary, release pressure before carrying out repairs.
♦ Hose connections 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 tension-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 / distilled water to standard VDE-0510
may be used for mixing. Tap water does not have the required
quality to ensure the coolant's function.
1.2 Safety regulations for working on fuel

supply
Caution
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
♦ Route lines of any kind so that the original routing can be
restored.
♦ Ensure that there is sufficient clearance to all moving
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♦ The fuel and the fuel lines in the fuel
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♦ The fuel system is also under pressure! Before opening
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♦ Wear eye and hand protection when performing any type

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When removing and installing fuel gauge sender or fuel pump

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(fuel delivery unit) from a full or partly full fuel tank, observe the
following:
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♦ Place the suction hose of an activated exhaust gas extraction

system close to the assembly opening of the fuel tank to ex‐
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extraction system is available, a radial fan with a displacement
greater than 15 m3/h can be used providing that motor is not
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

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Rep. gr.00 - Technical data
Caddy 2011 ➤
1.3 Safety precautions when using testers

and measuring instruments during a
road test
Note the following if testers and measuring instruments have to
be used during a road test:
♦ Test and measuring instruments must always be secured to
the rear seat and operated by a second person from this lo‐
cation.
♦ 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.
1.4 Safety precautions when working on in‐

jection system
♦ Persons wearing a pacemaker should not lean over the engine
compartment while the engine is running, as the injectors use
high voltage pulses.
♦ Do not open any fuel line connections while the engine is run‐
ning.
♦ Always switch off the ignition before connecting or discon‐
necting injection and glow plug system wiring or tester cables.
♦ Always switch off ignition before cleaning engine.
♦ The battery should only be disconnected and reconnected
with ignition switched off.
♦ Certain tests may lead to a fault being detected by the control
unit and stored. Therefore, after completing all gchecks
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1. Safety information 3
Caddy 2011 ➤
2 Identification
⇒ “2.1 Engine number/engine data”, page 4
2.1 Engine number/engine data

Four digit engine codes
The first 3 digits refer to the mechanical configuration of the en‐wagen AG. Volkswagen AG does
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The fourth digit indicates the output of the engine. It thdepends
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The engine number (“code letters” and “serial number”) -arrow-
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The engine codes can also be found on the vehicle data sticker.
The engine number consists of up to 9 characters (alphanumeric).
The first part (maximum 4 characters) makes up the “engine
rrectne
code”, and the second part (6 characters), the “serial number”. If
more than 999,999 engines were produced with the same code
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Identification code CAYD CAYE

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Manufactured 08.10 ► 08.10 ►
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Exhaust emissions fulfil EU5 standard EU5 standard

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Displacement 1.6 1.6

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Power kW at rpm 75/4400 55/3000 to 4000
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Bore Diameter, mm 79.5 Prote
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Stroke mm 80.5 80.5

Valves per cylinder 4 4
Compression ratio 16.5 16.5
Fuel, In accordance DIN EN 590 DIN EN 590
with
Firing order 1-3-4-2 1-3-4-2
Catalytic converter YES YES
Exhaust gas recirculation YES YES
Charging YES YES
Intercooler YES YES
particulate filter YES YES
4 Rep. gr.00 - Technical data

Caddy 2011 ➤
3 General information
⇒ “3.1 General notes on injection”, page 5
⇒ “3.2 General notes on the lubrication system”, page 5
⇒ “3.3 General notes on fuel system”, page 6
3.1 General notes on injection

⇒ page 257
♦ If fuel system has been opened, it must be bled before engine
is started ⇒ page 257 .
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♦ Fuel hoses in engine compartment must be secured only with Vol
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spring-type clips which conform to production standard.eThe d by ara
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use of crimp-type or screw-type clips is not permissible.
tho
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♦ The battery must be disconnected only with ignition ss switched c
ce
le
off. If a coded radio is installed, ascertain code before discon‐ un
pt
necting battery.
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♦ For trouble-free operation of electrical components, a voltage
pe
ility
of at least 11.5 V is necessary.
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♦ Do not use sealants containing silicone. Particles of silicone
hole
spec
drawn into the engine will not be burnt in the engine and dam‐
es, in part or in w
age the Lambda probe.
t to the co
♦ If, after fault finding, repairs or component tests, the engine
starts, runs for a short period and then stops, then the fault
rrectness of i
may be that the immobilizer is blocking the engine control unit.
In this case, the control unit must be adapted ⇒ Vehicle diag‐
l purpos
nostic tester.
♦ Certain tests may lead to a fault being detected by the control
nform
ercia
unit and stored. Therefore, after completing all the checks and
repairs, read the event memory and clear it if necessary
m
a
com
t
⇒ Maintenance ; Booklet 39 .
ion in
r
te o
♦ Vehicles with an airbag are fitted with a crash fuel shut-off. It
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reduces the danger of a fire in a crash as the fuel pump is
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switched off via the fuel pump relay.
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♦ When driver door is opened, fuel pump is activated for 2 sec‐
yi Co
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onds to generate pressure in fuel system. This improves the
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quality of the start behaviour.
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3.2 General notes on the lubrication system
agen
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Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter!
3. General information 5
Caddy 2011 ➤
Caution
Finding metal shavings or a large quantity of small metal par‐

ticles during engine repair could indicate that the crankshaft
bearings or conrod bearings are damaged. To prevent this
from causing further damage, perform the following repairs:
♦ Thoroughly clean oil passages,
♦ Renew oil spray jets,
♦ Renew engine oil cooler,wagen AG. Volkswagen AG doe
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♦ Renew oil filter element.
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Drain engine oil ⇒ Maintenance ; Booklet 39 ; Engine oil: Drain
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or extract; renew oil filter and replenish engine oil .
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Engine oil specifications ⇒ Maintenance ; Booklet 39 ; Service
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tables
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3.3 General notes on fuel system
h re
hole
spec
To prevent the high-pressure fuel pump from running while it is
es, in part or in w
t to the co
empty and to ensure that the engine starts quickly after parts have
been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel high-
rrectness of i
pressure pump are removed or renewed, initial fuel filling must
be carried out.
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♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
nform
ercia
sure pump) or fuel filter is removed or renewed

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♦ Fuel system must be bled before starting engine for first time.
at
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♦ If the high-pressure fuel pump is removed or renewed, the fuel

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system must be bled before engine is started for the first time.
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♦ Initial fuel filling procedure ⇒ page 257 .

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• Clean tools and workbench etc. before working on injection
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system. t. C rig
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pyri by
• Thoroughly clean all joints and surrounding areas before dis‐
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mantling.
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Prote AG.
• When removing components, seal all open connections im‐

mediately with suitable, clean protective caps.
• Do not remove sealing caps from components until immedi‐
ately prior to installation. Removed components should be
kept in new, sealable plastic bags (use the original new part
packaging if possible).
• Before installation, check injectors and their surroundings vis‐
ually; they must be undamaged and free of lint. Ensure that
the injector bore is clean. If necessary, clean injector bore.
• Only cleaning set - VAS 6811- may be used for cleaning the
sealing surface of the injector bore.
• For detailed information on how to use the cleaning set as well
as the order in which its components are applied, refer to the
⇒ operating manual provided with the cleaning set - VAS
6811- .
• If high-pressure lines are not renewed, they must be labelled
on removal. High-pressure fuel lines must always be re-instal‐
led in their original positions (i.e. on the same cylinder).
• The following components and seals/O-rings must always be
renewed when the injectors are removed and installed: “cop‐

Caddy 2011 ➤
per seal”, “O-ring for injector bore”, “O-ring for injector return
connection”, “injector return connection clip”
• The following components and seals/O-rings must always be
renewed when an injector is renewed: “copper seal”, “O-ring
for injector shaft” and “O-ring for injector return connection”
“injector return clip”
• Always fit new copper seals for the injectors. Check all new O-
rings for damage before installing. O-rings must be moist when
installed (assembly oil or clean engine oil). Use assembly tool
to install the “O-ring for injector return connection”.
• Take care not to damage the injectors when removing the old
copper seals.
. Volkswage
• Align high-pressure klinesgen AG
swa free from tension.dFirst
oes tighten all
n AG
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unions hand-tight
by Vand then tighten to torque.
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• Never attempt
ut
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r tee
or
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• When working
s on any parts of the high-pressure fuel system,
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tools may only be used for loosening and tightening pipe un‐
nl
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ions. All other components must always be removed and
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installed by hand without using tools or other equipment.
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• Disassembling individual common rail components is not per‐
wit
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mitted.
h re
hole
spec
• The components should be replaced as complete units if faul‐
es, in part or in w
ty.
t to the co
• Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine. rrectness of i
• Do not carry out any installation work on common rail system
l purpos
whilst engine is running.

• In particular, do not open or release high-pressure lines and
nform
ercia
electrical connectors.
m
at
• All cable ties that are opened or cut through during removal
om
io
must be secured in the same position during installation.

n
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• When the fuel system is open: do not work with compressed

at
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air if this can be avoided. Try not to move the vehicle.

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• Also ensure that no diesel fuel comes into contact with the
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coolant hoses. Should this occur, the hoses must be cleaned
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immediately. Damaged hoses must be renewed. opyri
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3. General information 7
Caddy 2011 ➤
4 Repair notes
⇒ “4.1 Rules for cleanliness when working on fuel supply system”,
page 8
⇒ “4.2 Rules for cleanliness when working on injection system”,
page 8
⇒ “4.3 Rules for cleanliness when working on turbocharger”, page
9
⇒ “4.4 Foreign objects in engine”, page 9
4.1 Rules for cleanliness when working on

fuel supply system
When working on the fuel supply/injection system, carefully follow
the “5 rules” below:
♦ Thoroughly clean all joints and surrounding areas before dis‐
mantling.
♦ Place removed parts on a clean surface and cover them over.
Use lint-free cloths only!
♦ If repair work cannot be performed immediately, cover new
parts which have been removed from their packing.
♦ Install only clean parts; do not remove new parts from pack‐
aging until immediately before installing. Do not use any parts
which have not been stored in their packaging (e.g. in a tool
box).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
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4.2 Rules for cleanliness when working on y Volkswa
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When working on the fuel supply/injection system, carefully
ss follow
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the “5 rules” below:
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mantling.
ab
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h re
hole
spec
es, in part or in w
parts which have been removed from their packing. t to the co

aging until immediately before installing. Do not use any parts
rrectness of i
which have not been stored in their packaging (e.g. in a tool

box).
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move the vehicle.
nform
mercia
at
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ion
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or
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ate
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Caddy 2011 ➤
n AG. Volkswagen AG do
lkswage4-cylinder diesel engine
es n (1.6 l engine, common rail) - Edition 09.2016
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4.3 Rules for cleanliness when working on
autho tee
or
ac
turbocharger
ss
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Caution
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If a mechanical fault is found on the turbocharger, e.g. a de‐
wit
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stroyed compressor impeller, just renewing the turbocharger is
hole
not enough. To avoid subsequent damage, the following work
spec
must be carried out:
es, in part or in w
t to the co
♦ Check air filter housing, air filter element and intake hoses
for soiling.
rrectness of i
♦ Check the whole charge air path and charge air cooler for
foreign objects.
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If foreign objects are found in the charge air system, the charg‐
ed air routing must be cleaned and the charge air cooler must
nf
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o
be renewed, if necessary.
rm
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When working on the turbocharger, pay careful attention to the
thi
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sd
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following rules for cleanliness:

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mantling.
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parts which have been removed from their packing.
aging until immediately before installing. Do not use parts that
have been kept unpackaged (for example in toolboxes).
♦ Transportation and protective packaging and sealing caps
must be removed only immediately before fitting.
♦ When making repairs, remove oil from connection and hose
ends.
♦ When installing, does not use any fluid containing oil, silicone
or grease.
move vehicle unless absolutely necessary.
4.4 Foreign objects in engine
Note
If large quantities of swarf or metal particles (caused, for example,

by partial seizure of the crankshaft or conrod bearings) are found
in the engine oil when performing repairs, clean the oil passages
thoroughly and renew the engine oil cooler in order to prevent
subsequent damage.
4. Repair notes 9
Caddy 2011 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 10
⇒ “1.2 Separating engine from gearbox”, page 22
⇒ “1.3 Separating engine from dual clutch gearbox”, page 23
⇒ “1.4 Securing engine on engine and gearbox support”,
page 25
⇒ “1.5 Installing engine”, page 26
1.1 Removing engine
Special tools and workshop

equipment required
♦ Lifting tackle - 3033-
♦ Hose clamps to 25 mm -
3094-
♦ Torque wrench (5 to
50 Nm) - V.A.G 1331- n AG. Volkswagen AG do
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♦ Torque wrench (40 to d b ua
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200 Nm) - V.A.G 1332- tho tee
or
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♦ Stepladder - VAS 5085- ss
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un
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♦ Workshop hoist - VAS
an
d
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6100-
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es, in part or in w
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10 Rep. gr.10 - Removing and installing engine

Caddy 2011 ➤
♦ Engine plug set - VAS 6122-
♦ Drip tray for workshop hoist - VAS 6208-
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♦ Pliers for spring-type clips - VAS 6362-
erm
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t to the co
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♦ tensioning straps - T10038-
om
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1. Removing and installing engine 11

Caddy 2011 ➤
♦ Ratchet ring spanner - T10384-
♦ Transportation lock - T10403-
Note
♦ Read out radio anti-theft code as the battery earth strap has AG. Volkswagen AG d
to be disconnected during the next work steps. agen oes
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♦ The engine is removed forwards together with the gearbox. orised
nte
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♦ All cable ties that are opened or cut through when sthe
s engine
a ra
c
is removed must be renewed in the same position when the
ce
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nl
engine is installed.
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erm
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ility
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WARNING
wit
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hole
When doing any repair work, especially in the engine compart‐

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

es, in part or in w
t to the co
tions:
♦ Route all the various lines and electrical wiring so that they
are in their original positions.
rrectness of i
♦ e.g. for fuel, hydraulics, activated charcoal filter system,

l purpos
coolant and refrigerant, brake fluid, vacuum.

♦ Ensure that there is sufficient clearance to all moving or
nf
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hot components
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Removing
thi
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sd
iva
– Remove air filter housing with air mass meter and connecting
r
rp
cu
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pipe ⇒ page 305 .

f
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ng
t.
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op
– Disconnect earth strap at battery with ignition switched off ⇒ C py
t. rig
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
gh ht
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battery.
op Vo
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing

and installing battery .
– Remove battery carrier. To do this, unscrew bolts -arrows-.
– Detach vacuum line -arrow- on brake servo.
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ss ce
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– Open clip -2- and pull off fuel return hose -1-.
wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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om
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– Open clip and pull off fuel supply line -arrow- from high pres‐
or c
sure pump.
thi
te
sd
iva
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f
en
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t.
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Cop py
t. rig
gh ht
pyri by
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Prote AG.

Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine, common
en AG. V rail)ag-eEdition
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– Unscrew bolts -arrows-. ed
b ara
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h
– Disconnect electrical connectorau -1- for coolant shortage indi‐
t ra
c
cator switch - F66- and pushss coolant expansion tank to side.
ce
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nl
pt
du
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itte
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erm
ab
ility
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wit
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Unclip coolant hose bracket -1- by pushing to side.
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nf
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orm
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thi
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sd
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t.
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Cop py
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– Loosen bolt -1-.
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cted agen
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– Unscrew bolt -2- and nut -3-.
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
(fuel hoses -5- and -6- remain connected).
– Collect any escaping fuel.
– Remove noise insulation ⇒ General body repairs, exterior;
Rep. gr. 66 ; Body front; Noise insulation .
– Drain coolant ⇒ page 187 .
Vehicles with air conditioning system
– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 87 .
– Unbolt refrigerant lines -arrow- ⇒ Heater, air conditioning sys‐

tem; Rep. gr. 87 at lock carrier.
Continued for all vehicles:
– Remove lock carrier ⇒ General body repairs, exterior; Rep.
gr. 50 ; Body, front; Lock carrier .

Caddy 2011 ➤
– Unscrew bolt -arrow- and place filler neck for windscreen

washer system reservoir to one side.
– Remove coolant expansion tank and place on engine.
AG. Volkswagen AG d
– Pull off vacuum hoses -1- and -2- for charge air control.
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– Disconnect connections. db ara
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s
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hole
spec
es, in part or in w
t to the co
♦ -1- Exhaust gas temperature sender 3 - G495-
rrectness of i
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♦ -3- Lambda probe - G39-
nform
mercia
a
com
tion in
r
te o
thi
s
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t.
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– Pull out wiring connector -1- for exhaust gas temperature
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sender 4 - G648- from bracket -2- behind battery, release and
cop Vo
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separate.
agen
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– Guide lines out of brackets on plenum chamber bulkhead and

on turbocharger.
– Remove plenum chamber bulkhead ⇒ General body repairs,
exterior; Rep. gr. 50 ; Body, front; Plenum chamber bulkhead .
– Remove engine control unit from its bracket ⇒ page 321 .

Caddy 2011 ➤
– Release connector for engine wiring harness -arrow- and pull

off from engine control unit.
– Open catch -A- of feed-through in plenum chamber bulkhead

and pull out upper part upwards. Remove engine wiring har‐
ness from cable guide.
AG. Volkswagen AG d
agen oes
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b ara
– Unscrew bolt -arrow- (captive bolt). Twistrise intake hose -A-
d
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clockwise out of its holder and removeut it.
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un
pt
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erm
ab
ility
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ole,
spec
t to the co
rrectne
– Disconnect plug-in connectors for heat exchanger -arrows- on

plenum chamber bulkhead.
ss 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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t.
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Cop py
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gh ht
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Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Unscrew positive cable -arrow- from starter at central electrics

and place cable on engine.
– Detach connectors -1- and-2- from left longitudinal member of

vehicle.
– Remove engine wiring harness from cable guide.
– Unbolt earth cable on gearbox.
– Place engine wiring harness on engine.
Vehicles with dual clutch gearbox:
– Remove selector mechanism from gearbox ⇒ Power trans‐
mission; Rep. gr. 34 .
AG. Volkswagen AG d
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d b ara
– rise
Release catch on mechatronic connector by pulling -arrow- nte
ho eo
and pull connector
s a off.
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s
Vehicles with manual gearbox:
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nl
pt
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itte
– Remove selector mechanism from gearbox ⇒ Power trans‐

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ab
mission; Rep. gr. 34 .

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es, in part or in w
t to the co
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– Unscrew bolt -3-.

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orm
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Prote AG.

Caddy 2011 ➤
– Remove bolts -arrows- and lay clutch slave cylinder aside. Do

not open hydraulic system.
– Guide clutch slave cylinder under strut -1-.
– Disconnect all connectors between starter, gearbox and body.
– Pull off connector -2- from exhaust gas pressure sensor 1 -

G450- .
– Unscrew bolts -3- and -4-.
AG. Volkswagen AG d
agen oes
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– Unclip lines for exhaust gas pressure sensor 1 - G450- by Vto‐
o l not
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ara
gether with retainer -1- from upper toothed belt guard.
rise d
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– Move exhaust gas pressure sensor 1 - G450- ss awith lines to‐ ra
c
wards the rear.
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nl
pt
du
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itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
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orm
m
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om
n in
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thi
te
sd
iva
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t.
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Cop py
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rig ht
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Prote AG.

AG. Volkswagen AG d
agen oes
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d by Caddy gu 2011 ➤
ara
ise nte
4-cylinder diesel engine
thor (1.6 l engine, common rail) - Edition 09.2016
eo
au ra
ss c
– Unscrew bolt -1- from exhaust gas pressure sensor 1 - G450-
ce
e
nl
pt
bracket.
du
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itte
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– Remove exhaust gas pressure sensor 1 - G450- bracket.
erm
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ility
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es, in part or in w
t to the co
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nf
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thi
te
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– Undo bolt -arrow- in upper bracket of particulate filter. Loosen
f
en
ng
t.
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securing bolt on cylinder head one turn.
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– Detach connector from oil level and oil temperature sender -

G266- .
– Remove right drive shaft cover.

– Remove drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shaft; Removing and installing
drive shaft .

Caddy 2011 ➤
– Fasten the two drive shafts to the suspension strut with the
tensioning straps - T10038- .
– First unscrew bolt -1-.

– Then, undo bolts -2- and -3-.
Vehicles with auxiliary heater
– Clamp off coolant hoses -1- and -2- with hose clips up to
25 mm - 3094- and pull coolant hoses from auxiliary heater.
AG. Volkswagen AG d
Continued for all vehicles: agen oes
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– Remove securing clamp -1- between particulate filter and tur‐

t to the co
bocharger.
rrectness of i
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tion in
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Prote AG.

Caddy 2011 ➤
– Loosen securing nuts above particulate filter bracket -1- using

ring ratchet spanner - T10384- .
– Unscrew securing nuts -2- for particulate filter bracket on
crankcase.
– Push particulate filter aside and secure on plenum chamber
bulkhead by suitable means.
Note
Check that all hose and line connections between engine, gear‐
box and body have been detached.
AG. Volkswagen AG d
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pt
an
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– Use lifting tackle - 3033- and workshop hoist - VAS 6100- to

itte
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support »engine/gearbox assembly« in installation position.
rm
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Vibration damper end:
wit
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• Position 2.
hole
spec
es, in part or in w
Flywheel end:
t to the co
• Position 8.
rrectness of i
l purpos
nform
ercia
– Remove securing bolts -arrows- of assembly mounting on en‐

m
gine.
a
com
tion in
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Prote AG.
– Remove securing bolts -arrows- of assembly mounting on

gearbox.
Note
Carefully guide »engine/gearbox assembly« when removing to

avoid damage to body.
– Slightly lift »engine/gearbox assembly« and remove forwards.

Caddy 2011 ➤
– Check needle roller bearing -arrow- in crankshaft. If it is dam‐

aged or has turned blue, it must be renewed ⇒ page 77 .
– If it is not damaged, grease lightly with high-temperature
grease - G 052 133 A2- .
Secure engine to engine and gearbox support - VAS 6095A- to
carry out repairs ⇒ page 25 .
1.2 Separating engine from gearbox

Special tools and workshop equipment required
♦ Hook - 10 - 222 A /2-
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♦ Workshop hoist - VAS 6100- yV
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♦ Lifting tackle - T40013-

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priv
cum
for
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Cop py
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by
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Prote AG.

Caddy 2011 ➤
Sequence of operations
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- . Volkswa AG. gen AG
agen does
– Attach lifting tackle - T40013- to gearboxVoand
lksw close lock. not
gu
by ara
ed
– Attach workshop hoist - VAS 6100- riswith hooks - 10 - 222 A/ nte
2- to lifting tackle. tho eo
au ra
c
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t to the co
rrectness of i
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– Unscrew bolts -1- and -2- and remove starter from gearbox.
nform
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a
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tion in
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Prote AG.
– Unscrew bolts -1, 3, 4- from gearbox/engine connection.

– Pull gearbox off engine.
Note
Disregard -items 2, 5, A-
1.3 Separating engine from dual clutch

gearbox

Caddy 2011 ➤
en AG. V
olkswagen AG
ag does
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♦ Lifting eye bolt - 3368- ed
by ara
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t to the co
rrectne
♦ shackles - 10 - 222 A /12-
ss o
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♦ Workshop hoist - VAS 6100- Prote AG.
• Engine/gearbox assembly removed, eye bolt - 3368- has been
screwed into gearbox.
– Attach workshop hoist - VAS 6100- with shackle - 10 - 222 A /
12- to eye-head bolt - 3368- .

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
– Pull off both breather caps -arrows- and close using
olkssuitable
w not
yV gu
plugs to achieve an oil-tight seal. se
d b ara
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ri
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– Unscrew bolts securing gearbox to engine.
au
t ra
c
ss
– Pull gearbox off engine.
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pt
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t to the co
1.4 Securing engine on engine and gearbox
rrectness of i
support
l purpos
nform
ercia
♦ Lifting tackle - 3033-

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Prote AG.
♦ Engine and gearbox support - VAS 6095A-
♦ Workshop hoist - VAS 6100-

Caddy 2011 ➤
• Gearbox detached from engine.
– Attach lifting tackle - 3033- as follows and lift slightly with
workshop hoist - VAS 6100- .
Flywheel end: position 4.
Vibration damper end: position 8.
– Secure engine on engine and gearbox support

lksw
- VAS 6095A- .
AG. Vo agen AG
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1.5 Installing engine t to the co

Install in reverse order, noting the following:
rrectness of i
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Note
nf
ercia
When renewing the engine/cylinder head, note that the plug in the
rm
m
cylinder head must be renewed. This plug seals the oil passage
atio
m
against the exterior.

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n in
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WARNING
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It is essential to refer to TPI 2030906/1 before installing engine. Cop py
t. rig
Not adhering to these instructions can lead to damage to the gh ht
yri by
cylinder head or cylinder head cover.
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Prote AG.
Note
♦ Renew bolts tightened through an additional specified angle.

♦ Renew self-locking nuts and bolts, and seals, O-rings and
gaskets.
♦ Hose unions and air intake pipes and hoses must be free of
oil and grease before installation.
♦ Secure all hose connections with the hose clips corresponding
to original equipment ⇒ Electronic parts catalogue (ETKA) .
♦ Attach cable ties in all the same places when installing.

Caddy 2011 ➤
– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
– Check that intermediate plate is hooked into sealing flange

and pushed onto dowel sleeves -arrows-.
Fastening, dual clutch gearbox to engine
AG. Volkswagen AG d
agen oes
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es, in part or in w
t to the co
rrectness of i
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om
ion
c
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ate
do
priv
cum
for
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t.
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gh ht
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Prote AG.

Caddy 2011 ➤
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AG. Volksw- aEdition
gen AG 09.2016
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M12 - 80 Nm. ris
ed
b ran
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❑ If 18 mm insert - au
t or
ac
T10179- is used: 65 Nm. ss
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nl
pt
M10 - 40 Nm.
du
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- Arrows point towards dowel
ab
ility
sleeves ot p
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Prote AG.

Caddy 2011 ➤
Fastening manual gearbox to engine

Item Bolt Nm
1 M12 x 55 80
2 1) M12 x 150 80
3 M10 x 50 40
4 M12 x 60 80
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M6 x 8gen AG 10does no
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A d b Dowel sleeves for centring ara
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• 1) Also ut
securess astarter ra
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• 2) Cover plate for flywheel

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Vehicles with manual gearbox
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– If clutch release bearing is worn, renew it ⇒ Rep. gr. 30 .
is n
h re
ole,
– Lightly grease gearbox input shaft splines with grease for
spec
clutch plate splines ⇒ Electronic parts catalogue (ETKA) .
t to the co
– Check centring of clutch plate.
– Install clutch slave cylinder ⇒ Power transmission; Rep. gr.
rrectne
30 .
– Install gearbox selector mechanism and adjust it, if necessary
ss
⇒ Power transmission; Rep. gr. 34 .
o
cial p
f inform
– Install cables with cable support bracket ⇒ Power transmis‐
mer
sion; Rep. gr. 34 .

atio
om
n
– Install hydraulic line for hydraulic clutch ⇒ Power transmis‐
c
i
or
n thi
sion; Rep. gr. 30 .

te
sd
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– Install gearbox selector mechanism and adjust it, if necessary

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fo

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Vehicles with dual clutch gearbox C py
ht. rig
rig ht
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Repairing clutch ⇒ Power transmission; Rep. gr. 30 . co Vo
by lksw
cted agen
Prote
– Install gearbox selector lever cable and adjust it, if necessary
AG.
– Check needle roller bearing -arrow- in crankshaft. If it is dam‐

aged or has turned blue, it must be renewed ⇒ page 77 .
– If it is not damaged, grease lightly with high-temperature
grease - G 052 133 A2- .
– Guide engine/gearbox assembly into body.
– When installing »engine/gearbox assembly«, ensure sufficient
clearance to subframe.

Caddy 2011 ➤
Note
♦ Screw in bolts -2- and -3- first.

♦ Then screw in bolt -1-.
– Adjusting assembly mountings ⇒ page 42 .
Note
♦ After working on particulate filter, ensure it is installed free of

stress.
♦ Renew self-locking nuts, seals, gaskets and securing clamps.
Caution
Avoid damaging flexible joint behind particulate filter. When

removing and installing:
♦ Do not allow the decoupling element to kink by more than
10°.
♦ Install decoupling element so that it is not under tension.
♦ Do not damage wire mesh on decoupling element.
AG. Volkswagen AG d
– Install particulate filter ⇒ page 341 . agen oes
olksw not
y V gu
b ara
– Bolt drive shafts to gearbox ⇒ Running gear, axles, steering;
rise
d
nte
Rep. gr. 40 ; Drive shaft; Removing and installing drive
aut shafts .
ho eo
ra
ss c
ce
le
– Install heat shield for right drive shaft -1- ⇒ Power transmis‐
un
pt
an
d
sion; Rep. gr. 34 ; Removing and installing gearbox .

itte
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erm
ab
– Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐
ility
ot p
moving and installing starter .
wit
is n
h re
– Installing radiator ⇒ page 209 .
ole,
spec
– Connect coolant hoses with plug-in connector to heat ex‐

t to the co
changer for heater.
– Install exhaust gas pressure sensor 1 - G450-
rrectne
– Install washer fluid reservoir filler pipe with filler neck.

– Electrical connections and routing ⇒ Current flow diagrams,
ss o
Electrical fault finding and Fitting locations.

cial p
f inform
– Install battery mounting and battery ⇒ Electrical system; Rep.

mer
gr. 27 ; Battery; Removing and installing battery .

atio
om
n
c
i
or
n thi
te
sd
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cum
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fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– When fitting intake connecting pipe to turbocharger, ensure

that intake connecting pipe is correctly seated on stud of tur‐
bocharger. -arrow-.
– Install air filter housing ⇒ page 306 .
– Check oil level ⇒ page 165 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body, front; Lock carrier .
– Charge air conditioner ⇒ Heating, air conditioning; Rep. gr.
87 .
– Observe notes after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting
agen
battery
AG. Volkswagen AG.
do w es n
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byV ua
ed ran
Caution ho
ris tee
t or
au ac
ss
Danger of destroying control units through overvoltage.
ce
e
nl
pt
du
♦ Never use battery charging equipment for boost starting.
an
itte
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erm
ab
ility
ot p
– Add coolant ⇒ page 187 .
wit
, is n
h re
hole
– Filling fuel system ⇒ page 257 .
spec
es, in part or in w
– Read event memories of all control units.
t to the co
– Clear all entries in event memory which may have occurred
during installation ⇒ Vehicle diagnostic tester.
rrectness of i
– Check headlight adjustment and correct if necessary ⇒ Main‐
l purpos
tenance ; Booklet 39 .
– Install noise insulation ⇒ General body repairs, exterior; Rep.
nform
ercia
gr. 66 ; Body - front; Noise insulation .

m
at
Torque settings
om
ion
c
in t
r
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32

o
his
ate
do
riv
♦ ⇒ “2.2 Assembly overview - particulate filter”, page 331

p
cum
for
♦ ⇒ “2.1 Assembly overview - catalytic converter”, page 329

en
ng
t.
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op py
♦ ⇒ “6.1 Assembly overview - air filter housing”, page 305 t. C rig
gh ht
pyri by
♦ Drive shafts; Assembly overview - drive shafts ⇒ Rep. gr. 40 ;
co Vo
by lksw
cted
Assembly overview - drive shafts .
agen
Prote AG.
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.

gr. 66 ; Assembly overview - noise insulation .

Caddy 2011 ➤
2 Assembly mounting
⇒ “2.1 Assembly overview - assembly mountings”, page 32
⇒ “2.2 Removing and installing motor mounting”, page 35
⇒ “2.3 Removing and installing engine bracket”, page 37
⇒ “2.4 Supporting engine in installation position”, page 40
⇒ “2.5 Adjusting assembly mountings”, page 42
2.1 Assembly overview - assembly mountings
1 - Double stud
❑ Renew after removal
❑ Specified torque and
tightening sequence
⇒ page 34
2 - Engine support
❑ Removing and installing
⇒ page 32
3 - Bolt
❑ Specified torque and AG. Volkswagen AG d
tightening sequence lksw
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not
⇒ page 34 d by Vo gu
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4 - Bolt utho eo
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❑ Renew after removal ss c
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❑ 40 Nm +90°
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5 - Cross-piece
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ility
6 - Bolt
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hole
spec
❑ 20 Nm +90°
es, in part or in w
t to the co
7 - Bolt
rrectness of i
❑ 20 Nm +90°
l purpos
8 - Bolt
nform
ercia
❑ 60 Nm +90°
m
9 - Engine mounting (hydraulic

a
com
tio
mounting)
n in
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thi
❑ With support arm.

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Caution
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t.
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op
Damage
♦ to the mem‐ C py
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brane will result in loss of
gh ht
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hydraulic fluid and thus
cop Vo
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impair functionality.
agen
Prote AG.
❑ The membrane can be found on the underside of the engine mounting ⇒ page 33 .
❑ In the event of damage to the membrane, renew engine mounting.

Caddy 2011 ➤
10 - Pendulum support
11 - Bolt
❑ Renew after removal AG. Volkswagen AG d
agen oes
olksw not
❑ Observe specified sequence
d by V
when removing and installing
gu ⇒ page 34
ara
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❑ Observe specified
ut
hor
torque ⇒ page 34 eo
ra
sa c
12 - Bolt s
ce
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nl
pt
du
an
itte
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❑ Observe specified sequence when removing and installing ⇒ page 34
erm
ab
ility
❑ Observe specified torque ⇒ page 34
ot p
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13 - Bolt
h re
hole
spec
es, in part or in w
❑ Observe specified sequence when removing and installing ⇒ page 34
t to the co
❑ Observe specified torque ⇒ page 34
14 - Bolt
rrectness of i
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❑ 60 Nm +90°
nf
ercia
15 - Bolt
orm
m
atio
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❑ 40 Nm +90°
o
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16 - Gearbox mounting
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❑ With support arm.

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17 - Gearbox support
t.
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Cop py
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18 - Bolt opyri
gh by
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❑ Specified torque ⇒ Power transmission; Rep. gr. 34

c by lksw
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Prote AG.
19 - Bolt
20 - Support
21 - Bolt
Membrane of engine mounting

The membrane -arrow- must not be damaged.
– If membrane is damaged, renew engine mounting
⇒ page 35 .
2. Assembly mounting 33
Caddy 2011 ➤
Pendulum support
Always observe size and strength class of the bolt. Different tor‐
que specifications apply.
Caution
As of gearbox production date 28 05 7, Heli Coil inserts are

installed in the threaded connections to pendulum support in
manual gearboxes 02Q. Identification ⇒ Rep. gr. 34
Use a bolt with hardness class 10.9 for this and all other gear‐
boxes.
If there is no HeliCoil insert in the 02Q gearbox, use class 8.8
bolts and the corresponding torque setting.
Tighten only if pendulum support is bolted to gearbox.

Always renew after removing.
Torque setting
Component Torque setting
Bolt A: M10 x 35, property class 40 Nm +90°
8.8
Bolt A: M10 x 35, property class 50 Nm +90°
10.9
Bolt B: M10 x 75, property class 40 Nm +90°
8.8
Bolt B: M10 x 75, property class 50 Nm +90°
10.9
Bolt C: M14 x 1.5 x 70 100 Nm +90°
Pendulum support - tightening sequence

Removing AG. Volkswagen AG d
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– First unscrew bolt -1-. d by V gu
ara
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– Then unscrew bolts -2- and -3-. utho eo
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Installing s
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un
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– First screw in bolts -2- and -3-.

an
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– Then screw in bolt -1-.

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Engine bracket - specified torques and installation sequence

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Note
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Renew bolts for engine bracket.

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– Tighten bolts in 3 stages in the sequence shown:

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stage Bolts Specified torque/further turning angle

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1st -1 to 3- 7 Nm.
i
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2nd -1 to 3- 40 Nm.
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3rd -1 to 3- Turn 180° further.

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Cop py
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34
cop Vo
by lksw
Rep. gr.10 - Removing and installing engine Prote
cted AG.
agen
lkswage es n Caddy 2011 ➤
o ot g
yV 4-cylinder diesel engineran (1.6 l engine, common rail) - Edition 09.2016
d b ua
ir se tee
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2.2 ss
a
Removing and installing motor mounting ac
ce
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nl
pt
du
an
itte
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erm
♦ Spring-type clip pliers - VAS 6362-
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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♦ Torque wrench (5 to 50 Nm) - V.A.G 1331-

o
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or c
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Cop py
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Prote AG.
Removing
– Loosen hose clip -4- and remove air hose.

– Push washer fluid reservoir filler pipe with filler neck -2- to side.
Caddy 2011 ➤
– Unscrew bolts -arrows-.

– Disconnect electrical connector -1- for coolant shortage indi‐
cator switch - F66- and push coolant expansion tank to side.
AG. Volkswagen AG d
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aut ra
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spec
t to the co
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f inform
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sd
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Co
Cop py
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– Support engine in its installation position ⇒ page 40 .
ht
pyri by
Vo
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cted agen
Prote AG.
Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket - 10 - 222 A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
– Unscrew bolts -1- and -2- and remove connecting bracket.

– Unscrew bolts -3 … 6- and remove engine mounting.
Installing
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must be strictly adhered to.

Caddy 2011 ➤
– Fit engine assembly mounting in position. First, tighten bolts

-3- and -6- and then -1- and -2-.
– Use the spindle to bring the engine bracket to rest on the en‐
gine support.
– Insert bolts -4- and -5- and then tighten them.
– Adjusting assembly mountings ⇒ page 42 .
Torque settings
2.3 Removing and installing engine bracket

♦ Hose clamps to 25 mm - 3094-
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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Caddy 2011 ➤
swage es n
Removing byV
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– Loosen hose clip -4- and remove air hose. tho tee
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– Open quick-release fasteners -A- and -B- of fuel lines.
AG.

Caddy 2011 ➤

Note
♦ The assembly mounting may only be removed if the engine is

supported with support bracket - 10 - 222 A- !
♦ The engine bracket must be loosened only when the assembly
mounting has been removed.
– Unscrew bolts -1-

ageand
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. Volkand
swagremove
en AG
doeconnecting bracket.
w s no
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– Unscrew
ed
bbolts
yV -3 … 6- and remove engine gmounting.
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spec
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t to the co
– Clamp off coolant hoses using hose clamps to 25 mm - 3094-

and remove. To do this, release hose clips -arrows-.
rrectness of i
– Disconnect connector -3- on radiator outlet coolant tempera‐

l purpos
ture sender - G83- .

– Remove nut -1- and bolt -2-, remove right coolant pipe.
nf
ercia
– Remove front right wheel housing liner ⇒ General body re‐

rm
m
atio
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Front wheel

om
housing liner .
n in
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WARNING
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When raising and lowering engine using support bracket -
Co
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Note
The bolt -1- is accessible through an aperture in the wheel hous‐

ing. Raise and lower engine using spindle of support bracket - 10
- 222 A- to remove or start bolts -2- and -3-.
Caddy 2011 ➤
– Unscrew bolts of engine bracket in sequence -3…1-.

– Remove engine bracket upwards.
Installing
Caution
The tightening sequence and specified torques for the engine

bracket securing bolts must always be followed. Otherwise the
engine bracket can be stressed, causing it to break.
– Insert engine bracket from above.

AG. Volkswagen AG d
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Note ed by ara
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The bolt -1- is accessibless through an aperture in the wheel hous‐
a c
ing. Raise and lower engine using spindle of support bracket - 10
ce
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nl
pt
- 222 A- to remove or start bolts -2- and -3-.
du
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– Initially screw in new bolts hand-tight in the sequence
ility
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-1 to 3-.
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Tightening sequence for engine bracket
es, in part or in w
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– Tighten bolts in specified sequence to specified torque.
rrectness of i
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– Fit engine assembly mounting in position. First, tighten bolts

p
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-3- and -6- and then -1- and -2-.

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– Use the spindle to bring the engine bracket to rest on the as‐ C py
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sembly mounting.
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– Insert bolts -4- and -5- and then tighten them. cted agen
Prote AG.
♦ Ensure fuel hoses are seated correctly.

♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
♦ Add coolant ⇒ page 187 .
Torque settings
2.4 Supporting engine in installation posi‐

tion

Caddy 2011 ➤
♦ Support - 10 - 222 A-
♦ Hook - 10 - 222 A /2-
AG. Volkswagen AG d
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♦ Adapter - 10 - 222 A i/3- sed b ara
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♦ Adapter - 10 - 222 A /16-

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Caddy 2011 ➤
♦ Adapter - 10 - 222 A /30-
– Remove filler pieces from upper edge of left and right wings.
exterior; Rep. gr. 50 ; Plenum chamber bulkhead; Removing
and installing plenum chamber bulkhead .
– Remove air filter housing ⇒ page 306 .
– Remove intake hose on turbocharger ⇒ Item 2 (page 305) .
– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /30- ,
adapter - 10 - 222 A /3- and adapter - 10 - 222 A /16- as shown
in illustration.
AG. Volkswagen AG d
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d by ara
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– Attach hook - 10 - 222 A /2- to support eye and adapter - 10 -

pt
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– Take up weight of engine and gearbox on spindles.

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2.5 Adjusting assembly mountings

form
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Prote AG.

Caddy 2011 ➤
♦ Pliers for spring-type clips - VAS 6362-
AG. Volkswagen AG d
WARNING agen oes
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d by ara
e
When doing any repair work,thoespecially in the engine compart‐
ris nte
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ment, pay attention to thes afollowing
u due to the cramped condi‐ ra
c
tions: s
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nl
pt
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hot components
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t to the co
– Loosen hose clip -4- and remove air hose.

rrectness of i
Caution
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Risk of irreparable damage to electronic components when

nform
ercia
disconnecting battery .
m
♦ Comply with precautions when disconnecting battery .

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Caddy 2011 ➤
– Disconnect earth wire -arrow- from battery with ignition switch‐

ed off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
reconnecting battery .
– Remove battery and battery tray -arrows-.
Note
For reasons of clarity, diagram shows installation position with

fuel filter removed.
lkswage es n
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– Unscrew bolt -1-. aut or
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– Push washer fluid reservoir filler pipe with filler neck -2- to side.
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Caddy 2011 ➤

Note
It is only permissible to loosen the securing bolts for the assembly

mountings if the engine is supported on the support bracket -
10-222 A- .
– Unscrew engine mounting bolts -arrows- in succession and Volkswag

.
renew (if not already carried out on installing engine).
swa
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– First screw bolts in loosely. edb ara
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– Renew gearbox mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
rrectness of i
– First screw bolts in loosely.

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Motor mounting
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tion in
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45
Prote AG.
2. Assembly mounting
Caddy 2011 ➤ AG. Volkswagen AG d
4-cylinder diesel engineagen
ksw (1.6 l engine, common
oes rail) - Edition 09.2016
ol not
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– Using an assembly hor lever between engine bracket and support eo
ut
arm -1-, adjust
ss a position of engine until the specifications listed ra
c
below are obtained:
ce
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un
pt
an
• There must be a distance of -a- = 13.5 mm between engine
d
itte
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support -2- and right longitudinal member.
rm
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pe
ility
• The side of the engine support casting -2- must be aligned
ot
wit
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parallel to the support arm -1- (dimension -x- must be identical
h re
on both sides).
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
Distance -a- = 13.5 mm can also be checked with a rod of suitable
size, or similar.
l purpos
– Tighten bolts for engine mounting.
nform
ercia
Gearbox mounting
m
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tion in
– On the gearbox side, ensure that the edges of the support arm
r
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-2- and gearbox support -1- are parallel.
s
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• Dimension -x- must be identical on both sides of mounting.

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– Tighten bolts for gearbox mounting.

t.
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• Ensure that fuel lines are tight. opy
rig by
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c lksw
• Do not interchange supply line and return line (return line blue
by
cted agen
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or with blue marking, supply line black).
AG.
– Observe notes after connecting battery ⇒ Electrical system;

Rep. gr. 27 ; Disconnecting and reconnecting battery .
Torque settings

Caddy 2011 ➤
3 Motor cover
⇒ “3.1 Removing and installing engine cover”, page 47
3.1 Removing and installing engine cover

Removing
Caution
The engine cover retainer on the cylinder head cover can break
if not removed correctly. Always remove engine cover accord‐
ing to following instructions.
– Pull engine cover panel upwards out of fasteners in areas of AG. Volkswagen A
-arrows- and in sequence shown. To do this, grip as ofar
lkswbe‐
agen G do
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neath engine cover panel as possible. d by V ua
r e an
ris tee
Installing utho or
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nl
Caution
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Before installing engine cover panel, check the 4 securing el‐
ility
ot p
ements (ball sockets) in the correct positions. Reset to correct
wit
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position if necessary. Otherwise the engine cover panel may
h re
be damaged.
hole
spec
es, in part or in w
t to the co
– Press engine cover panel ball sockets into correct position.
rrectness of i
– Position engine cover panel on securing points and press cor‐
ners into fasteners.
l purpos
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Prote AG.
3. Motor cover 47
Caddy 2011 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - cylinder block”, page 48
⇒ “1.2 Assembly overview - sealing flange, belt pulley end”, page
50
⇒ “1.3 Assembly overview - poly V-belt drive without air condi‐
tioner compressor”, page 51
⇒ “1.4 Assembly overview - poly V-belt drive with air conditioning
compressor”, page 52
⇒ “1.5 Assembly overview - ancillary bracket”, page 53
⇒ “1.6 Removing and installing sealing flange on pulley end”,
page 53
⇒ “1.7 Renewing crankshaft oil seal - belt pulley end”,
page 56 AG. Volkswagen AG d
agen oes
ksw
⇒ “1.8 Removing and installing bracket for ancillaries”,
by Vol not
gu
ara
page 58 rise
d
nte
tho eo
⇒ “1.9 Removing and installing poly V-belt
ss awithout air conditioner
u ra
c
compressor”, page 61
ce
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un
pt
an
⇒ “1.10 Removing and installing poly V-belt with air conditioner
d
itte
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compressor ”, page 61
rm
ab
pe
ility
⇒ “1.11 Removing and installing tensioner for poly V-belt”,
ot
wit
, is n
page 63
h re
hole
spec
⇒ “1.12 Removing and installing vibration damper”, page 64
es, in part or in w
t to the co
1.1 Assembly overview - cylinder block
rrectness of i
Note
l purpos
♦ If you discover metal shavings or a large quantity of small

metal particles during engine repair, proceed as follows to
nform
ercia
prevent further damage:

m
a
com
♦ Thoroughly clean oil channels.

ion in
r
te o
♦ Renew engine oil cooler ⇒ page 172 .

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48 Rep. gr.13 - Crankshaft group

Caddy 2011 ➤
1 - Cylinder block
❑ Assembly overview -
pistons and conrods
⇒ page 80
sealing flange and fly‐
wheel ⇒ page 66 .
crankshaft
⇒ page 76 .
2 - Guide tube
❑ Renew O-ring
3 - Fastener
4 - Seals
5 - Oil filter bracket
❑ Assembly overview
⇒ page 171
6 - Bolt
❑ Tightening sequence
⇒ page 50 .
❑ 14 Nm +180°
7 - Bolt
❑ 13 Nm.
8 - Thermostat (4/2-way valve) AG. Volkswagen AG d
agen oes
ksw
❑ Thermostat is firmly in‐ by Vol not
gu
ara
stalled in valve. rised
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❑ Can only be renewed
aut as ra
c
a complete item
ss
ce
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nl

pt
du
an
itte
⇒ page 199
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9 - O-ring
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hole
10 - Lifting eye
spec
es, in part or in w
t to the co
11 - Holder
12 - Bolt
rrectness of i
Specified torque and tightening sequence ⇒ page 53

l purpos
13 - Bolt
❑ 20 Nm.
nform
ercia
14 - Oil pan
m
at
om
❑ Clean sealing surface before fitting.

ion
c
in t
r
❑ Silicone sealant ⇒ Electronic parts catalogue (ETKA)

o
his
ate
do
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15 - Bolt
p
cum
or
❑ 15 Nm.
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Prote AG.
1. Cylinder block (pulley end) 49

Caddy 2011 ➤
Tightening sequence for oil filter bracket

– First, tighten new upper left and lower right bolts.
– Tighten bolts in 2 stages:
1- 14 Nm.
2- Then, turn 180° further.
AG. Volkswagen AG d
agen oes
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pt
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ility
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es, in part or in w
1.2 Assembly overview - sealing flange, belt pulley end
t to the co
1 - Bolt
rrectness of i
l purpos
❑ Do not additionally oil

the thread and shoulder
nf
ercia
o
❑ 180 Nm +135°
rm
m
atio
m
2 - Crankshaft pulley
o
n in
or c
❑ With or without mark
thi
e
(depending on version)
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❑ Contact surface be‐
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tween toothed belt pul‐

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ley and crankshaft must Cop py
be free from oil
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❑ Can only be fitted in one
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cted
position
agen
Prote AG.
3 - Crankshaft oil seal for belt

pulley end
❑ Do not additionally oil or
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing ⇒ page 56
4 - Sealing flange at belt pulley
end
❑ Must seat on dowel
pins.
❑ Silicone sealant ⇒ Elec‐
tronic parts catalogue
(ETKA)
⇒ page 53

Caddy 2011 ➤
4-cylinder diesel engine (1.6 l engine,
en common
AG. Volkswarail)
gen A-GEdition 09.2016
ag does
ksw not
y Vol gu
5 - Cylinder block ed
b ara
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6 - Dowel pin au
t ra
c
ss
7 - Bolt
ce
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nl
pt
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❑ Specified torque and tightening sequence ⇒ page 51
itte
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ility
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Sealing flange at belt pulley end - Prescribed torque and tighten‐
h re
ing sequence
hole
spec
es, in part or in w
– Tighten bolts for sealing flange at belt pulley end in the se‐
t to the co
quence -1 … 10- in 3 stages as follows:
1. Screw in bolts -1 … 10- by hand until heads make contact.
rrectness of i
2. Tighten bolts -1 … 6- in diagonal sequence to 15 Nm. l purpos
3. Tighten bolts -7 … 10- to 15 Nm.
nform
mercia
at
om
ion
c
in t
or
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e
1.3 Assembly overview - poly V-belt drive without air conditioner compressor
at
do
priv
cum
for
en
ng
t.
1 - Belt pulley and vibration
yi Co
op py
damper t. C rig
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❑ Fitting possible in one cop Vo
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position only. The holes cted agen
Prote AG.
are offset.
⇒ page 64
2 - Alternator
⇒ Electrical system;
Rep. gr. 27 ; Alternator
3 - Ancillary bracket
Assembly overview
⇒ page 53
4 - Poly V-belt
⇒ page 61

Caddy 2011 ➤
1.4 Assembly overview - poly V-belt drive with air conditioning compressor
1 - Poly V-belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
⇒ page 61
2 - Tensioning element
3 - Belt pulley and vibration
damper
❑ Offset holes make as‐
sembly possible in one
position only
4 - Bolt
❑ 10 Nm +90°
5 - Dowel sleeves
❑ Check for correct seat‐
ing in ancillary bracket.
6 - Holder
⇒ page 58
7 - Bolt lkswage es n
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byV ua
❑ Renew after removal ir se
d ran
tee
ho
❑ 20 Nm +180° aut or
ac
ss
8 - Alternator
ce
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nl
pt
du
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⇒ Electrical system;
erm
ab
Rep. gr. 27
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9 - Air conditioner compressor

h re
hole

spec
es, in part or in w
⇒ Heating, ventilation, air conditioning system; Rep. gr. 87 .

t to the co
10 - Dowel sleeves
❑ Check for correct seating in ancillary bracket.
rrectness of i
l purpos
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orm
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by
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Prote AG.

Caddy 2011 ➤
1.5 Assembly overview - ancillary bracket

– Install bolts as follows:
♦ Bolts -1- and -2- M10 x 52.
♦ Bolts -3- and -4- M10 x 30. AG. Volkswagen AG d
agen oes
olksw not
V gu
♦ Bolts -5- and -6- M10 x 60. d by ara
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– Tighten bolts in 4 stages in the sequence shown: aut ra
c
ss
ce
le
stage Bolts Specified torque/further turning angle
un
pt
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d
itte
1st -1 to 6- Screw in to contact by hand.
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2nd -1 to 6- 40 Nm.
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3rd -3- and -4- Turn 45° further.
h re
4th -1, 2, 5, 6- Turn 90° further. ole,
spec
t to the co
rrectne
1.6 Removing and installing sealing flange
on pulley end
ss o
cial p
f in
form
mer
♦ Retainer - 3415-
atio
om
n
c
i
or
n thi
te
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t.
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by c lksw
cted agen
Prote AG.
♦ Assembly tool - T10053-

Caddy 2011 ➤
AG. Volkswagen AG d
♦ Torque wrench - V.A.G 1332- agen oes
olksw not
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d by ara
ise nte
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rm
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ility
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hole
spec
es, in part or in w
t to the co
Removing
rrectness of i
– Remove toothed belt ⇒ page 121 .
l purpos
– Lock crankshaft pulley -1- in position using counterhold tool -

3415- .
nform
ercia

m
a
com
tio
– Remove crankshaft pulley -1-.
n in
r
te o
thi
– Remove sump ⇒ page 159 .
s
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fo
en
ng
t.
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Cop py
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– Unscrew bolts -1 … 10- and carefully remove sealing flange
p by
o Vo
by c lksw
from the glued joint. Prote
cted AG.
agen
– Remove sealing flange. If necessary, loosen sealing flange

using light blows with a rubber headed hammer.
– Remove sealant residues from cylinder block with a flat scra‐
per.
– Remove sealant residue from sealing flange with a rotating

plastic brush (wear protective goggles).
– Clean sealing surfaces. They must be free of oil and grease.
Installing
Note
♦ Check the expiry date of the sealant.

♦ The sealing flange must be installed within 5 minutes of ap‐
plying the silicone sealant.
♦ The sealant bead must be no thicker than 2 to 3 mm. Excess
sealant can find its way into the sump and block the strainer
in the suction line and drip on the sealing surface of the crank‐
shaft seal.
♦ Before applying sealant bead, cover sealing surface of oil seal
with a clean cloth.

Caddy 2011 ➤
– Cut off nozzle on tube at front marking (∅ of nozzle approx.

3 mm).
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s a ac
– Apply a thin bead of sealant at the edge of the joint between
s
ce
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the cylinder block and the sump -arrows-.

un
pt
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rm
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pe
ility
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es, in part or in w
t to the co
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– Apply silicone sealant bead as shown in the illustration to clean

sealing surface of sealing flange.
nform
mercia
a
com
tion in
r
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Prote AG.

Caddy 2011 ➤
– Thinly coat lower sealing surface -shaded area- on sealing

flange with sealant.
– Fit sealing flange immediately and lightly tighten all bolts.
Note
♦ When fitting sealing flange with oil seal installed use the guide
sleeve - T10053/1- .
♦ Leave the sealant to dry for approx. 30 minutes after assem‐
bly. Only then fill with engine oil.
– Tighten sealing flange securing bolts diagonally and alternate‐

ly.
– Install crankshaft pulley.
– Install sump ⇒ page 159 .
– Install toothed belt and adjust valve timing ⇒ page 121 .
Torque settings
♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,
page 50
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 119
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 157
1.7 Renewing crankshaft oil seal - belt pulley end
AG. Volkswagen AG d
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Caddy 2011 ➤

equipment required
♦ Seal puller - 3203-
♦ Retainer - 3415-
♦ Torque wrench
(5 … 50 Nm) - V.A.G 1331-
♦ Torque wrench (40 to AG. Volkswagen AG d
agen oes
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200 Nm) - V.A.G 1332- byV
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es, in part or in w
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cted
Removing
agen
Prote AG.

– Lock crankshaft pulley -1- in position using counterhold tool -
3415- .
– Remove crankshaft pulley -1-.

Caddy 2011 ➤
– To guide seal extractor - 3203- , screw centre bolt into crank‐

shaft as far as stop by hand.
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
from the outer part and lock in position with the knurled screw.
– Oil threaded head of seal extractor.
– Screw oil seal extractor forcibly as far as possible into oil seal.
– Loosen knurled screw and turn inner part against crankshaft
until the oil seal is pulled out.
Installing
AG. Volkswagen AG d
agen oes
Note Volksw not
gu
d by ara
ise nte
r
The oil seal sealing lip must not be additionally
ut
ho oiled or greased. eo
ra
s a c
s
ce
le
– Remove oil residues from crankshaft journal with a clean cloth.

un
pt
an
d
itte
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erm
ab
– Fit guide sleeve - T10053/1- onto crankshaft journal.
ility
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– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
wit
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nal.
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
– Press oil seal in as far as stop with press sleeve - T10053- and atio
om
central bolt.
n
c
i
or
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– Install crankshaft pulley.

t
sd
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– Install and tension toothed belt ⇒ page 121 .

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Torque settings
Co
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♦ ⇒ “1.2 Assembly overview - sealing flange, belt pulley end”,
ht
pyri by
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page 50 by c lksw
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Prote AG.
1.8 Removing and installing bracket for an‐

cillaries

Caddy 2011 ➤
Removing
– Remove high-pressure pump ⇒ page 291 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator .
Vehicles with air conditioning system
WARNING
The air conditioner refrigerant circuit must not be opened.
– Unbolt air conditioner compressor from ancillary bracket Then,

secure air conditioner compressor to lock carrier ⇒ Heating, G. Volkswagen
ventilation, air conditioning system; Rep. gr. 87 ; Air condi‐
lksw
agen
A AG do
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tioner compressor; Removing and installing air conditioner
by
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compressor . orised ran
te
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Continued for all vehicles: s au ra
c
s
ce
le
– Remove idler pulleys -1- and -2-. Unscrew bolt for toothed belt
un
pt
an
d
guard -arrow-.
itte
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es, in part or in w
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– Loosen securing bolt for engine bracket -1-.

nform
mercia
a
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tion in
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te o
thi
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Caddy 2011 ➤ yV
olks ot g
b u
4-cylinder diesel engine (1.6 l riengine,
se
d common rail) - Edition 09.2016arante
tho eo
au ra
– Unscrew bolts -6….1- and remove
ss ancillary bracket. c
ce
e
nl
pt
Installing
du
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ab
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♦ Note any fitted sleeves in ancillary bracket and renew missing
wit
ones if necessary. , is n
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spec
♦ Renew all bolts to be tightened with torque angle.
es, in part or in w
t to the co
♦ Tack engine bracket bolt before tightening ancillary bracket
securing bolt.
rrectness of i
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– Tighten securing bolts in sequence -1…6-.
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– Install high-pressure pump, install toothed belt and adjust
Co
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valve timing ⇒ page 291 . t. C rig
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pyri by
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Prote AG.
– Renew and tighten bolt -1- of engine bracket ⇒ page 32 .

– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator .
– Detach air conditioner compressor from lock carrier, then fit it
to ancillary bracket, and tighten it ⇒ Heating, ventilation, air
conditioning system; Rep. gr. 87 ; Air conditioner compressor;
Removing and installing air conditioner compressor .
– Installing high-pressure pump ⇒ page 291 .
– Filling/bleeding high-pressure pump/fuel system
⇒ page 257 .
Torque settings
♦ ⇒ “1.5 Assembly overview - ancillary bracket”, page 53
♦ Starter; Assembly overview - starter ⇒ Electrical system; Rep.
gr. 27 ; Assembly overview - starter

Caddy 2011 ➤
1.9 Removing and installing poly V-belt

without air conditioner compressor
Note
The poly V-belt repair kit with tools contains the assembly tool -
T10367- and illustrated instructions.
Removing
– Cut through poly V-belt.
– Further work sequence is carried out as described in illustrated
instructions.
The illustrated instructions accompany the spare part.
Installing agen
AG. Volkswagen AG d
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Install in reverse order, dnoting
by
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ara
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If poly V-belt was installed
ut
ho offset: eo
ra
s a c
s
– Do not remove poly V-belt.
ce
le
un
pt
an
– Turn engine at crankshaft. When doing this, guide poly V-belt
d
itte
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until it is properly seated on belt pulley.
erm
ab
ility
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– Install noise insulation ⇒ General body repairs, exterior; Rep. wit

is n
gr. 66 ; Body - front; Noise insulation . h re

ole,
spec
1.10 Removing and installing poly V-belt with

t to the co
air conditioner compressor

rrectne
♦ Pin - T10060 A-
ss o
cial p
f inform
mer
atio
om
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Prote
Removing
AG.


Caddy 2011 ➤
Vehicles with auxiliary heater

– Unscrew bolt -2- from coolant pipe bracket -1- of auxiliary
heater.
– Unscrew bolts -1- of coolant pipes for auxiliary heater -2- from
drive shaft heat shield.
– Mark running direction of poly V-belt.
– Turn tensioning device in direction of arrow to relieve tension

on poly V-belt.
AG. Volkswagen AG d
agen oes
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ab
– Align holes -arrows- with each other. Lock tensioning element

ility
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using locking pin - T10060 A- .

wit
, is n
h re
hole
– Remove poly V-belt.

spec
es, in part or in w
Installing
t to the co

rrectness of i
Note
l purpos
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nf
ercia
nator, air conditioner compressor) are secure.

orm
m
atio
♦ When fitting poly V-belt, check direction of belt rotation and

om
proper seating of belt in belt pulleys.

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thi
te
sd
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rig ht
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by lksw
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Prote AG.

Caddy 2011 ➤
– Fit poly V-belt on poly V-belt pulley as shown in illustration.

1- Crankshaft
2- Tensioning element
3- Alternator
4- Air conditioner compressor
On completing work:
– Start engine and check belt running.
1.11 Removing and installing tensioner for

poly V-belt
Removing n AG. Volkswagen AG do

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– Remove poly V-belt ⇒ page 61 . ir se
d b ua
ran
o tee
h
Notes on hose connections with screw-type
aut
clamps or
ac
⇒ page 235 ss
ce
le
un
pt
– Open clips -1- and -2- and remove connecting hose.

an
d
itte
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erm
ab
– Remove radiator cowl with radiator fan - V7- and remove right
ility
ot p
radiator fan - V35- ⇒ page 208 .

wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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by
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Prote AG.

Caddy 2011 ➤
– Undo and remove bolts -arrows- from charge air pipe and de‐
tach connector -1- from charge pressure sender - G31- .
Notes on hose connections with screw-type clamps
⇒ page 235
– Open clamp -2-.
– Detach coolant hose -3- from retainers and remove charge air
pipe.
– Remove air conditioner compressor. Do not disconnect refrig‐
erant lines from air conditioner compressor.
– Refrigerant circuit remains closed.
– Use suitable means to suspend air conditioner compressor on
vehicle body ⇒ Heating, ventilation, air conditioning system;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Unscrew securing bolt -2-.

– Remove tensioning element for poly V-belt -1-.
Installing
– Install poly V-belt ⇒ page 61 .
Torque settings
♦ ⇒ “1.4 Assembly overview - poly V-belt drive with air condi‐
tioning compressor”, page 52
lkswage es n
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1.12 Removing and installing vibration damp‐ ir se
d b ua
ran
tee
er tho
u or
a ac
ss
ce
le
un
pt
an
d
itte
♦ Torque wrench - V.A.G 1331-

y li
erm
ab
ility
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wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
i
or
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te
sd
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pr
cum
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fo
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ng
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 ➤
Removing
pairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Remove poly V-belt ⇒ page 48 .
– Remove cap for vibration damper.
– Unscrew bolts -1- while counterholding on centre bolt.
– Remove vibration damper -2-.
Installing
• Installation position: hole -arrow- in vibration damper must
align over protrusion on crankshaft pulley.
Torque settings
lkswage es n
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nl
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es, in part or in w
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at
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ion
c
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
2 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - flywheel”, page 66
⇒ “2.2 Removing and installing flywheel”,Vpage
olkswa
67
AG. gen AG
agen do
⇒ “2.3 Removing and installing
olksealing
sw flange on gearbox
es n
side”,
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page 68 sed b ua
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2.1 Assembly overview - flywheel
ut or
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d
itte
1 - Bolt
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❑ 60 Nm +90°
is n
h re
ole,
2 - Two-part flywheel
spec
❑ Offset holes make as‐
t to the co
sembly possible in one
position only
rrectne
⇒ page 67
s
3 - Sender wheel
s o
cial p
f
❑ For engine speed send‐
inform
er - G28-
mer

atio
m
⇒ page 68
o
n
c
i
or
n thi
e
4 - Engine speed sender -

t
sd
va
G28-
i
o
pr
cum
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fo

en
ng
t.
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⇒ page 356
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5 - Bolt rig ht
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❑ 5 Nm.
by
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Prote AG.
6 - Dowel pin
7 - Adapter
❑ Must seat on dowel
pins.
❑ Do not damage or bend
when assembling.
❑ Installing ⇒ page 67
8 - Sealing flange with oil seal
❑ With sender wheel for
engine speed.
❑ Renew complete only.
❑ Do not additionally oil or grease the oil seal sealing lip.
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
❑ Use support sleeve supplied when installing.
❑ Removing and installing ⇒ page 68
9 - Bolt

Caddy 2011 ➤
Install intermediate plate.

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel pins -arrows at bottom-.
Sealing flange on gearbox side - specified torque and tightening

sequence
– Tighten bolts in 2 stages as follows:
stag Bolts Torque setting
e
1st -1 to 6- Screw in to contact by hand.
2nd -1 to 6- In diagonal sequence and in stages;
final torque 15 Nm
2.2 Removing and installing flywheel

Special tools and workshop equipment required agen
AG. Volkswagen AG d
oes
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V gu
♦ Retainer - 3067- ed by ara
nte
ris
ho eo
aut ra
ss c
ce
le
un
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itte
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pe
ility
ot
wit
, is n
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es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
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tion in
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te o
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iva
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t.
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Cop py
t. rig
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pyri by
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o
by c lksw
cted agen
Prote AG.
2. Cylinder block, gearbox end 67

Caddy 2011 ➤
Removing
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .
– Insert counterhold - 3067- in hole on cylinder block.
• Do not unscrew bolts with an power impact wrench. Unscrew
them by hand (risk of damage to flywheel).
Note
♦ Item A: tighten bolts.

♦ Item B: loosen bolts.
– Unscrew bolts -1-.

Installing
Torque settings
♦ ⇒ “2.1 Assembly overview - flywheel”, page 66
2.3 Removing and installing sealing flange

on gearbox side
♦ Insert tool, 24 mm - V.A.G 1332/11-
lkswage es n
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ir se tee
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nl
pt
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itte
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ility
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wit
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hole

spec
es, in part or in w
t to the co
rrectness of i
l purpos
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
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Prote AG.

Caddy 2011 ➤
♦ Depth gauge - VAS 6082-
♦ Bolt M6x35 (qty. 3)

♦ Bolt M7x35 (qty. 2)
Pressing out sealing flange with sender wheel
• Gearbox removed.
– Remove flywheel ⇒ page 67 .
Note
For reasons of clarity, the illustrations show the work procedure

with the engine removed.
– Remove intermediate plate -1- from dowel sleeves

-arrows A-.
– Guide intermediate plate -1- upwards.
– While doing so, pull retaining lug -arrow B- of intermediate
plate -1- out of recess behind sealing flange.
– Turn crankshaft on bolt for toothed belt pulley until crankshaft
is at “TDC” position ⇒ page 121 . AG. Volkswagen A gen G do
swa es n
– Remove sump ⇒ page 159 b.y Volk ot g
ua
d ran
se
– Remove engine speedthosender
ri - G28- ⇒ page 356 . tee
or
au ac
ss
ce
le
un
pt
– Unscrew bolts -arrows- for sealing flange -1-.

an
d
itte
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ab
pe
ility
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es, in part or in w
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tion in
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te o
thi
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iva
do
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Cop py
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69
cop Vo
by lksw
Prote
cted AG.
agen 2. Cylinder block, gearbox end
Caddy 2011 ➤
– To press off, screw 3 bolts M6 x 35 into sealing flange -1-

-arrows-.
Note
The sealing flange -1- is pressed off crankshaft -3- together with
the sender wheel -2-.
– Screw bolts alternately into sealing flange not more than 1/2
. Volkswagen AG
turn at a time. swa
gen AG does
k not
Vol g
– Remove sealing flange
se
d b-1- together with sender wheel -2-.uara
y
n i tee
or
Pressing in sealing aflange
ut
h
with sender wheel or
ac
ss
ce
e
nl
pt
du
an
itte
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Note
erm
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ility
ot p
♦ The sealing flange with a PTFE seal is equipped with a sealing
wit
, is n
lip support ring -2-. This support ring serves as a fitting sleeve
h re
hole
and must not be removed prior to installation.
spec
es, in part or in w
♦ Sealing flange and sender wheel -1- must not be separated or
t to the co
turned after removal from packaging.
♦ The sender wheel -1- is held in its installation position on the
rrectness of i
locating pin of the assembly tool - T10134- ⇒ page 70 .
l purpos
♦ Sealing flange and oil seal form one unit and must only be
renewed together with the sender wheel. nf
ercia
♦ The assembly tool - T10134- is held in its position relative to

orm
the crankshaft by a guide pin inserted into a hole in the crank‐

m
atio
m
shaft ⇒ page 70 .
o
n in
or c
thi
te
sd
iva
Set-up of assembly tool - T10134- :

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rp
cu
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f
en
ng
A - Clamping surface
t.
yi Co
op py
B - Nut
t. C rig
gh ht
pyri by
Vo
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C - Assembly housing by c lksw
cted agen
Prote AG.
D-
Locating pin
E - Hexagon socket head bolt (qty. 2)
F - Guide pin for petrol engines (red knob)
G-
Guide pin for diesel engines (black knob)
H - Knurled screws (qty. 3)
I - Inner part

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
rised
nte Caddy 2011 ➤
o e
aut
h
4-cylinder diesel engine (1.6 l engine,orcommon
ac rail) - Edition 09.2016
ss
ce
le
Fitting sealing flange with sender wheel on assembly tool -
un
pt
an
d
T10134- :
itte
y li
rm
ab
– Screw on nut -B- until just before it touches the clamping sur‐
pe
ility
face -A- of the threaded spindle.
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Clamp assembly device - T10134- at clamping surface -A- of
nform
ercia
threaded spindle in a vice -1-.

m
a
com
t
– Push assembly housing -C- downwards until it rests against
ion in
nut -B-.
r
te o
thi
s
iva
• Inner part of assembly tool and assembly housing must be at
do
r
rp
c
same height.
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– If fitted, remove securing clip -arrow- from new sealing flange

-1-.
Note
Do not take the sender wheel out of the sealing flange or rotate it
out of position.
– Place sealing flange with front side facing down on a clean

level surface.
– Push sealing lip support ring -1- downwards in
-direction of arrow- until it rests against flat surface.

Caddy 2011 ➤
• Upper edge of sealing lip support ring -1- and front edge of
sealing flange -2- must align -arrows-.
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– Place sealing flange -1- with front side facing downwards ed b onto ara
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assembly tool - T10134- so that locating pin -D- tis hor seated in eo
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• The sealing flange must rest flat against the assembly tool.
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• Only 2 of the 3 knurled screws -H- can be screwed in.
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– Screw knurled screws -H- into sealing flange -1-.
l purpos
– Press sealing flange -1- and sealing lip support ring -2- against
surface of assembly tool - T10134- whilst tightening knurled
screws.
nf
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– This prevents the locating pin from slipping out of the sender
m
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wheel hole.
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– When installing sealing flange, ensure that sender wheel re‐
thi
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mains fixed in assembly tool.

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Mounting assembly tool - T10134- with sealing flange -1- on
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crankshaft flange:
Prote AG.
• The crankshaft flange must be free of grease and oil.

• Engine is at “TDC” position ⇒ page 121 .
– Screw on nut -B- until it reaches end of threaded spindle.
– Press threaded spindle of assembly tool - T10134- in
-direction of arrow-, until nut -B- rests against assembly hous‐
ing -C-.
– Align flat side of assembly housing to sealing surface of cyl‐
inder block on sump side.

Caddy 2011 ➤
– Attach assembly tool - T10134- together with sealing flange

-1- to crankshaft flange -2-.
– To do this, screw hexagon socket head bolts -E- into crank‐
shaft flange (approx. 5 full turns) using a hexagon key.
– Push guide pin for diesel engines (black knob) -G- into crank‐
shaft flange.
– To guide sealing flange -1-, screw two M6×35 mm bolts

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into cylinder block. lkswage does
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Mounting assembly tool - T10134- with sealing flange -1- on
crankshaft flange:
rrectness of i
• The crankshaft flange must be free of grease and oil.
l purpos
• Engine is at “TDC” position ⇒ page 121 .

nform
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– Press threaded spindle of assembly tool - T10134- in

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-direction of arrow-, until nut -B- rests against assembly hous‐ on
c
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or
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ate
– Align flat side of assembly housing to sealing surface of cyl‐

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inder block on sump side.

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– Attach assembly tool - T10134- together with sealing flange
C py
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-1- to crankshaft flange -2-.
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cted
– To do this, screw hexagon socket head bolts -E- into crank‐
agen
Prote AG.
shaft flange (approx. 5 full turns) using a hexagon key.
shaft flange.

Caddy 2011 ➤
– To guide sealing flange -1-, screw two M6×35 mm bolts -2-

into cylinder block.
Bolting assembly tool - T10134- onto crankshaft flange:

– Push assembly housing -C- by hand in -direction of arrow- until
sealing lip support ring -1- rests against crankshaft flange
-2-.
– Make sure that guide pin for diesel engines (black knob) -G-
is properly seated in hole in crankshaft. This ensures that the
sender wheel reaches its final installation position.
Note
Do not insert the guide pin for petrol engines (red knob) in the
threaded hole of the crankshaft.
– Tighten the two hexagon socket head bolts of assembly tool

hand-tight.
– Screw nut -B- by hand onto threaded spindle until it rests
against assembly housing -C-.
Pressing sender wheel onto crankshaft flange using assembly

tool - T10134- :
swage es n
– Tighten nut -B- of assembly tool - T10134- to 35 Nm. byV
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• After the nut has been tightened to 35 Nm, a small air gap tmust
ho tee
or
still be present between cylinder block and sealing flange au -1-. ac
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Checking sender wheel installation position on crankshaft:

rrectne
– Unscrew the two bolts -2- from cylinder block.

– Pull guide pin for diesel engines (black knob) -G- out of crank‐
ss
shaft flange.
o
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– Unscrew knurled screws -H- from sealing flange -1-.

form
mer
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– Unbolt assembly tool - T10134- from crankshaft flange, un‐

om
screwing hexagon socket head bolts -E- from crankshaft

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flange.
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– Remove sealing lip support ring.

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Prote AG.
Rep. gr.13 - Crankshaft group
Caddy 2011 ➤
– Position depth gauge - VAS 6082- on crankshaft flange -2-.
– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: dimension -a- = 0.5 mm
AG. Volkswagen AG d
– If specification is not achieved, press sender wheel furtherolkinswagen oes
not
⇒ page 75 . db
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– If specification is achieved, proceed with subsequent
tho work eo
steps ⇒ page 75 . s au ra
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Re-pressing sender wheel:
hole
spec
– Secure assembly tool - T10134- on crankshaft flange.
es, in part or in w
t to the co
– Make sure that locating pin of assembly tool - T10134- is prop‐
erly seated in sender wheel hole.
rrectness of i
– Tighten hexagon socket head bolts -E- by hand.
l purpos
– Push assembly tool - T10134- by hand against sealing flange

-1-.
nform
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– Screw nut -B- by hand onto threaded spindle until it rests

against assembly tool - T10134- .
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shaft flange.
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– Screw knurled screws -H- into sealing flange -1-.

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– To guide sealing flange, screw two M6×35 mm bolts -2- into op
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cylinder block.
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– Tighten nut -B- of assembly tool - T10134- to 40 Nm. Prote
cted AG.
agen
– Check sender wheel installation position on the crankshaft

again ⇒ page 74 .
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on the crankshaft
again ⇒ page 74 .
Assembling
Assembly is carried out in reverse sequence; note the following:
Torque settings

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Caddy 2011 ➤ byV ua
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3 Crankshaft
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⇒ “3.1 Assembly overview - crankshaft”, page 76
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⇒ “3.2 Crankshaft dimensions”, page 77
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⇒ “3.3 Renewing needle bearing in crankshaft”, page 77
spec
es, in part or in w
3.1 Assembly overview - crankshaft
t to the co
rrectness of i
1 - Bearing shells 1, 2, 4 and 5
❑ For bearing cap without
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oil groove.
❑ For cylinder block with
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oil groove
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❑ Do not interchange
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used bearing shells
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or c
(mark).
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2 - Bolt
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❑ To measure radial clear‐ C py
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ance, tighten to 65 Nm
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❑ 65 Nm +90°
Prote AG.
3 - Bearing cap
❑ Bearing cap 1: belt pul‐
ley end.
❑ Bearing cap 3 with re‐
cesses for thrust wash‐
ers.
❑ Bearing shell retaining
lugs in cylinder block
and bearing caps must
align.
4 - Thrust washer
❑ For bearing cap 3.
❑ Note fixing arrange‐
ment.
5 - Bearing shell 3
❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove
❑ Do not interchange used bearing shells (mark).
6 - Needle bearing
❑ Only vehicles with dual clutch gearbox.
7 - Crankshaft
❑ With toothed belt sprocket for oil pump drive. Toothed belt sprocket is not available as separate part.
❑ Axial clearance new: 0.07 to 0.17 mm, wear limit: 0.37 mm
❑ Measure radial clearance with Plastigage , new: 0.03 to 0.08 mm; wear limit: 0.17 mm
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 77 .

Caddy 2011 ➤
8 - Thrust washer
❑ For cylinder block, bearing 3
3.2 Crankshaft dimensions

(Dimensions in mm)
Crankshaft Conrod
main journal ∅ journal ∅
Basic dimension 54.00 -0.022 47.80 -0.022
-0.042 -0.042
3.3 Renewing needle bearing in crankshaft

Vehicles with dual clutch gearbox only.
♦ Adapter - Kukko 22/1-
AG. Volkswagen AG d
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♦ Puller - Kukko 21/2-

es, in part or in w
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♦ Pin - VW 207 C-
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Cop py
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Prote AG.
3. Crankshaft 77
Caddy 2011 ➤
Note
Vehicles with dual clutch gearbox, the needle bearing must be

installed in rear end of crankshaft.
Condition:
• Always renew needle bearing -arrow- after separating engine
and gearbox.
• The front edges of the inner puller must not be chipped.
AG. Volkswagen AG d
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Pulling out needle roller bearing
itte
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– Using a commercially available internal puller, e. g. KUKKO -
ility
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21/2- , and counter support, e.g. KUKKO - 22/1- , pull needle
wit
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bearing -1- out of crankshaft -2-.
h re
hole
spec
– The internal puller must be positioned behind the needle-and-
es, in part or in w
cage assembly -arrow-.
t to the co
rrectness of i
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Installing
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Cop py
– Clean bearing seat in crankshaft and apply as thin coating of
t. rig
gh ht
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grease.
p by
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– Drive needle bearing into crankshaft to installation depth using
Prote AG.
drift - VW 207 C- .

Caddy 2011 ➤
Installation depth: dimension -a- = 1.5 mm … 1.8 mm
Note
If the needle bearing is inadvertently driven in too far, it must be

renewed because it will be damaged when it is pulled out again.
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Prote AG.
3. Crankshaft 79
Caddy 2011 ➤
4 Pistons and conrods

⇒ “4.1 Assembly overview - pistons and conrods”, page 80
⇒ “4.2 Checking pistons and cylinder bores”, page 82
⇒ “4.3 Piston and cylinder dimensions”, page 83
⇒ “4.4 Separating new conrod”, page 83
⇒ “4.5 Measuring piston projection at TDC”, page 84
⇒ “4.6 Checking radial clearance of conrods”, page 85
⇒ “4.7 Removing and installing oil spray jets”, page 86
4.1 Assembly overview - pistons and conrods

AG. Volkswagen AG d
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1 - Conrod bolt byV
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❑ Renew after removal horis nte
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❑ Oil threads and contact ss a ra
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❑ Use old bolt for measur‐
an
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ing radial clearance.
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❑ 30 Nm +90°
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2 - Conrod bearing cap
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spec
❑ The conrod bearing cap
es, in part or in w
only fits in one position
t to the co
and only on the appro‐
priate conrod due to the
breaking procedure
rrectness of i
(cracking) separating
the cap from the conrod.
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❑ Mark cylinder allocation

in colour -B-.
nform
ercia
❑ Installation position:
m
markings -A- face to‐

a
com
wards belt pulley end. tion in

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te o
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3 - Sleeve bearing
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❑ Installation position
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⇒ page 82
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❑ Mark used bearing . Cop py
shells for re-installation
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rig ht
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but not on bearing sur‐ copy Vo
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face. cted agen
Prote AG.
❑ Renew bearing shells
worn down to base lay‐
er.
❑ Note version: upper
bearing shell (towards
piston) made of a more
wear-resistant material.
Identification on new
bearing shells: black line on bearing surface in area of joint
❑ Ensure firm seating
4 - Connecting rod
❑ Renew as set only.
❑ With industrially cracked conrod bearing cap
❑ Separate new conrod ⇒ page 83
❑ Mark cylinder allocation in colour -B-.

Caddy 2011 ➤
❑ Installation position: markings -A- towards belt pulley end
❑ Axial clearance, wear limit: 0.37 mm
❑ Measuring radial clearance ⇒ page 85
5 - Locking ring
6 - Piston pin
❑ If difficult to move, heat piston to approx. 60°C.
❑ Remove and install using drift - VW 222 A- .
7 - Piston
❑ With combustion chamber.
❑ Mark installation position and cylinder number ⇒ page 81 .
❑ Checking ⇒ page 83
❑ Install using piston ring clamp.
❑ Piston and cylinder dimensions ⇒ page 83 .
❑ Measuring cylinder bore ⇒ page 83
❑ Measuring piston projection at “TDC” ⇒ page 84
8 - Piston rings
❑ Compression rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to remove and install.
❑ Installation position: marking “TOP” or side with lettering towards piston crown
❑ Measuring ring gap ⇒ page 82
❑ Measuring ring-to-groove clearance ⇒ page 82
9 - Piston ring
❑ Oil scraper ring
❑ Offset gap 120° relative to lower compression ring
❑ Use piston ring pliers to remove and install. AG. Volkswagen AG d
agen oes
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❑ Measuring ring gap ⇒ page 82 ed by
V gu
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❑ Measuring ring-to-groove clearance ⇒ page ut
h82
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Installation position and allocation of piston to cylinder
itte
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• If worn pistons are to be reinstalled, mark their allocation to

ility
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the cylinder on the piston crown. Only use paint for this.
wit
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• Arrow on piston crown points to pulley end -arrow-.

hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
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ion
c
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do
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for
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Cop py
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Vo
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Prote AG.
4. Pistons and conrods 81

AG. Volkswagen AG d
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Caddy 2011 ➤ d by V gu
ara
e
4-cylinder diesel
horis engine (1.6 l engine, common rail) - Edition
nte
eo 09.2016
aut ra
ss c
Installation position of bearing shells in conrods
ce
le
un
pt
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– Centre bearing shells on conrod and on conrod bearing cap. d
itte
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erm
ab
• Dimension -a- must be identical on both sides.
ility
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spec
t to the co
rrectness
4.2 Checking pistons and cylinder bores
o
cial p
f inform
mer
atio
m
♦ Micrometre 75 - 100 mm - VAS 6071-

o
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Cop py
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rig ht
py by
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by lksw
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Prote AG.
Measuring piston ring gap

– Push piston ring at right angles to cylinder wall from above
down into cylinder bore to approx. 15 mm from bottom end of
cylinder.
– Push in using a piston without piston rings.
Piston ring New Wear limit
mm mm
1st compression ring 0.20 to 0.40 1.00
2nd compression ring 0.20 to 0.40 1.00
Oil scraper ring 0.25 to 0.50 1.00
Measuring ring-to-groove clearance

– Clean annular groove of piston before check.
Piston ring New Wear limit
mm mm
1st compression ring 0.06 to 0.09 0.25
2nd compression ring 0.05 to 0.08 0.25
Oil scraper ring 0.03 to 0.06 0.15

AG. Volkswagen AG d
agen oes
olksw not Caddy 2011 ➤
byV gu
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rised
4-cylinder diesel engine (1.6ranl tengine,
ee common rail) - Edition 09.2016
tho
or
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Checking piston
ss
ce
le
un
pt
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
an
d
itte
ton pin axis with a 75 to 100 mm external micrometer.
y li
rm
ab
pe
ility
• Maximum deviation from nominal dimension: 0.04 mm.
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wit
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Nominal dimension ⇒ page 83
h re
hole
spec
es, in part or in w
t to the co
Note
Piston must be changed if piston shaft reveals cracking.
rrectness of i
l purpos
Measuring cylinder bore
nform
mercia
Note
a
com
tion in
r
Cylinder bores must not be measured when the cylinder block is

te o
thi
secured to engine and gearbox support - VAS 6095A- , as meas‐
s
iva
do
r
urements may be incorrect.

rp
cum
fo
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ng
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– Measure at three points -c-, in direction -a- and direction -b-. Cop py
ht. rig
rig ht
• Maximum deviation from nominal dimension: 0.10 mm. py by
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Nominal dimension ⇒ page 83 Prote AG.
4.3 Piston and cylinder dimensions

Piston ∅ Cylinder bore ∅
Basic di‐ mm 79.353 79.5
mension
4.4 Separating new conrod

Note
♦ To avoid damage, only clamp the conrod lightly in a vice and

use protective jaw covers.
♦ On new conrods it is possible that the breaking point is not fully
separated. Proceed as follows if the conrod bearing cap can‐
not be removed by hand:
– Clamp conrod -1- below dashed line.

– Unscrew bolts -2- approx. 5 turns.

Caddy 2011 ➤
ks wage es
– Using a plastic hammer, carefully Vol knock against conrod bear‐
not
gu
by
ing cap -1- in directionriseof -arrow- until it is loose.
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4.5 Measuring piston projection at TDC
rrectness of i
l purpos
♦ Measuring tool - VW382-
nform
mercia
at
om
ion
c
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or
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ate
do
priv
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for
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
♦ Measuring plate - VW 385/17-
♦ Dial gauge - VAS 6079-
Test sequence
♦ Piston projection at TDC must be measured on all pistons
when installing new pistons or a short engine.

Caddy 2011 ➤
♦ If you have measured the piston projection and it is not same

for all pistons, use the highest value to determine the correct
gasket size.
♦ Depending on piston projection, fit the appropriate cylinder
head gasket according to following table.
♦ Turn the engine in an clockwise direction to carry out the
measurement.
– Secure dial gauge - VAS 6079- with measuring bridge -
VW 382/7- and measuring plate -VW 385/17- to cylinder block
as shown in the illustration.
Note
♦ To measure the piston projection at top dead centre, turn the

crankshaft clockwise.
♦ If different values are determined during the projection meas‐
urement, use the largest dimension for selecting the gasket.
– Measure the projection of each piston at the two points marked

with -arrows- (at the rear side and front side of the piston seen AG. Volkswagen AG d
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in the longitudinal direction of the engine). by
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– Install the appropriate cylinder head gasket depending
ho
r upon tee
ut or
piston projection, according to following table:
ss a ac
ce
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nl
Piston projection over upper Identification
pt
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edge of cylinder block in mm Holes/notches
itte
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0.91 to 1.00 1
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1.01 to 1.10 2
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1.11 to 1.20 3
spec
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t to the co
Note
rrectness of i
If different values are determined during the projection measure‐
ment, use the largest dimension for selecting the gasket.
l purpos
nform
ercia
4.6 Checking radial clearance of conrods

m
at
om

ion
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♦ Plastigage
his
ate
do
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Test sequence
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– Remove conrod bearing cap. Clean bearing cap and bearing

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op
journal. C py
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– Place a Plastigage corresponding to the width of the bearing op Vo
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on the journal or into the bearing shells. cted agen
Prote AG.
– Fit conrod bearing cap and tighten, but do not tighten with
turning angle. Do not rotate crankshaft.
– Remove conrod bearing cap again.
– Compare width of Plastigage with the measurement scale.
Radial clearance:
• Wear limit: 0.08 mm
– Renew conrod bolts.

Caddy 2011 ➤
Torque settings
♦ ⇒ “4.1 Assembly overview - pistons and conrods”, page 80
4.7 Removing and installing oil spray jets

♦ Torque wrench - V.A.G 1331- AG. Volkswagen AG d
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♦ Hexagon bit, long reach - T10545-
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Caddy 2011 ➤
Removing
– Turn crankshaft in direction of engine rotation until respective
pressure relief valve and oil spray jets are accessible.
Caution
Risk of damage to oil spray jets caused by deformation.

• Do not bend oil spray jets.
– Unscrew pressure relief valve -1- using Torx bit T40 -

T10545- .
– Remove oil spray jets -2-.
Installing
AG. Volkswagen A gen G do
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– Align guiding edge of oil spray
by
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lk with machined surface ofnot
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Oil spray jet with 24 Nm.
erm
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pressure relief
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Caddy 2011 ➤
15 – Cylinder head, valve gear

1 Cylinder head
⇒ “1.1 Assembly overview - cylinder head”, page 88
⇒ “1.2 Assembly overview - cylinder head cover”, page 91
⇒ “1.3 Removing and installing cylinder head”, page 93
⇒ “1.4 Removing and installing cylinder head cover”, page 109
⇒ “1.5 Removing and installing injector seals”, page 114
⇒ “1.6 Removing and installing vacuum pump”, page 117
⇒ “1.7 Checking compression”, page 117
1.1 Assembly overview - cylinder head
Note
♦ The plastic protectors fitted to protect the open valves must

only be removed immediately before fitting the cylinder head.
♦ When cylinder head is renewed, the coolant must be com‐
pletely renewed as well.
AG. Volkswagen AG d
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88 Rep. gr.15 - Cylinder head, valve gear

Caddy 2011 ➤
1 - Cylinder head
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal ⇒ page 90 .
❑ After renewing, renew
entire coolant.
❑ Check for distortion
⇒ page 90 .
⇒ page 93
2 - Window glass
3 - Cylinder head bolt
❑ Sequence when loosen‐
ing ⇒ page 91 .
❑ Specified torque and
tightening sequence
⇒ page 91
❑ Before installing, Vplace wage es n
olks ot g
washers in cylinder
ed by ua
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head horis tee
⇒ Item s2au(page
t
89) . or
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4 - Oil pressure switch - F1-
ce
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❑ Identification: green
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❑ 0.5 bar
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❑ If seal is leaking, nip

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open and renew.

h re
hole
spec

es, in part or in w
❑ 22 Nm.
t to the co
5 - Bolt
❑ 20 Nm.
rrectness of i
6 - Lifting eye
l purpos
7 - Glow plug
nform
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❑ 18 Nm.
m
8 - Gasket
com
tion in

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9 - Vacuum pump
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10 - Bolt
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❑ 10 Nm. t. Cop py
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11 - Clip p by
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12 - Radiator outlet coolant - G62- Prote AG.
13 - Sealing ring
14 - Bolt
❑ 10 Nm.
15 - Coolant hose connection
16 - Sealing ring
1. Cylinder head 89
Caddy 2011 ➤
17 - Bolt
❑ 25 Nm.
18 - Lifting eye
19 - Cylinder head gasket
❑ Observe identification ⇒ page 91 .
❑ After renewing, renew entire coolant.
20 - Hall sender - G40-
❑ For camshaft position.
21 - Bolt
❑ 10 Nm.
Glow plugs -arrows- project out of cylinderaghead.

en AG. V
olkswagen AG
do w es n
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Glow plugs -arrow- project out of cylinder
ed
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V
head. After removal, the ua
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cylinder head must not be placed
horis on the glow plugs. If necessary, tee
remove glow plugs ⇒ page a354
ut . or
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ility
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Checking cylinder head for distortion
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♦ Straightedge 500 mm - VAS 6075-
co Vo
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♦ Feeler gauge -1-
Max. permissible distortion: 0.1 mm

AG. Volkswagen AG d
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th4-cylinder
or diesel engine (1.6 l engine, common e o rail) - Edition 09.2016
au ra
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Note
an
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ab
ility
Reworking diesel cylinder heads is not permissible.
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Cylinder head gasket identification hole
spec
es, in part or in w
1- Part number
t to the co
2- Holes
3- Ignore
rrectness of i
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Note
nf
ercia
o
♦ Different thicknesses of cylinder head gasket are fitted de‐
rm
m
pending on the piston projection. When renewing gasket,
atio
m
install new gasket with same identification.

o
n in
or c
thi
♦ Piston projection at TDC must be determined when installing
te
sd
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new pistons or a short engine ⇒ page 80 .
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Observe sequence when loosening cylinder head bolts C py
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– Slacken cylinder head bolts in the sequence -1 … 10-. cop Vo
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Cylinder head - specified torque and sequence
Note
Renew bolts for cylinder head.
– Tighten bolts in 4 stages in the sequence shown:

stage Bolts Specified torque/turning further angle
1st -1 to 10- 35 Nm.
2nd -1 to 10- 60 Nm.
3rd -1 to 10- Turn 90° further.
4th -1 to 10- Turn 90° further.
1.2 Assembly overview - cylinder head cover
1. Cylinder head 91
Caddy 2011 ➤
1 - Bolt
❑ 5 Nm.
2 - High-pressure accumulator
❑ With injection pipes.
❑ Do not attempt to bend
injector pipes to a differ‐
ent shape.
3 - Bolt
❑ 22 Nm.
4 - Injector
❑ Piezo injector
⇒ page 279
5 - Bolt
❑ Initial specified torque:
2 Nm
❑ 8 Nm +270°
6 - Clamping piece
❑ One clamping piece for
2 injectors.
7 - Bush olkswagen AG
en AG. V
❑ Fastening for high-pres‐olkswag does
not
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❑ Renew if damaged
utho eo
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8 - Sealing ring s
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9 - Sealing ring
erm
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ility
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10 - Sealing cap
ole,
spec
11 - Cylinder head cover

t to the co

12 - Gasket
rrectne
❑ Renew if damaged or leaking

13 - Bolt
ss o
❑ Renew gasket if damaged

cial p
f inform
❑ Note tightening sequence ⇒ page 93

mer
atio
❑ 9 Nm.
om
n
c
i
or
14 - Wiring guide
thi
te
sd
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15 - Heat shield
i
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Cop py
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Prote AG.

Caddy 2011 ➤
Tightening sequence for cylinder head cover

– Tighten cylinder head cover bolts in the sequence -1 … 6-.
AG. Volkswagen AG d
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1.3 Removing and installing cylinder head
, is n
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spec
es, in part or in w
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equipment required
♦ Guide bolt - 3070-
rrectness of i
♦ Diesel injection pump lock‐
l purpos
ing pin - 3359-

♦ Crankshaft stop - T10050-
nf
ercia
or
♦ Retainer - T10051-
m
m
atio
om
♦ Puller - T10052-
n in
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♦ Bit XZN 10 - T10385-

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1. Cylinder head 93
AG. Volkswagen AG d
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Caddy 2011 ➤ autho eo
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4-cylinder diesel engine (1.6 l engine, common rail) - Edition 09.2016 ss c
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♦ Torque wrench - V.A.G
erm
ab
1331-
ility
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1332-
ole,
spec
♦ Socket set 1/4", 22-piece -
t to the co
VAS 5528-
♦ Engine bung set - VAS
6122-
rrectne
♦ Drip tray for workshop hoist
s
- VAS 6208-
s o
cial p
f i
♦ Vehicle diagnostic tester
nform
mer
atio
om
n
c
i
or
n thi
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Prote AG.
♦ Release lever - 80 - 200-

Caddy 2011 ➤
AG. Volkswagen AG d
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is n
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spec
t to the co
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cial p
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mer
atio
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Prote AG.
Note
♦ All cable ties which are opened or cut through when cylinder
head is removed must be fastened in the same position when
cylinder head is installed.
♦ All connectors which are separated during disassembly must
be reconnected in the original position when installing.
1. Cylinder head 95
AG. Volkswagen AG d
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Caddy 2011 ➤ orise nte
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4-cylinder diesel
aut engine (1.6 l engine, common rail) - Edition r a09.2016
c
ss
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Please observe the following points during all installation work,
ot
wit
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, is n
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itations:
hole
spec
es, in part or in w
t to the co
restored.
hot components
rrectness of i
l purpos
nform
ercia
Note
m
a
com
t
Glow plugs -arrow- project out of cylinder head. After removal, the
ion in
cylinder head must not be placed on the glow plugs. If necessary,
r
te o
thi
remove glow plugs ⇒ page 354 .
s
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do
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Removing
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– Remove plenum chamber bulkhead ⇒ General body repairs; C py
t. rig
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
gh ht
pyri by
Vo
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by c lksw
– Remove air filter housing with air mass meter and connecting cted agen
Prote AG.
pipe ⇒ page 305 .
– Detach vacuum line -2- from vacuum pump -1-.

– Detach these connectors:

♦ -3- Lambda probe - G39-

Caddy 2011 ➤

separate.
on turbocharger.

G450- .
– Unscrew bolts -3- and -4-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Unclip linesssfor exhaust gas pressure sensor 1 - G450- to‐
ce
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nl
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– Move exhaust gas pressure sensor 1 - G450- with lines to‐

y li
erm
ab
wards the rear.

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es, in part or in w
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nf
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Prote AG.
1. Cylinder head 97
Caddy 2011 ➤
– Unscrew bolt -1- from exhaust gas pressure sensor 1 - G450-

bracket.
– Remove exhaust gas pressure sensor 1 - G450- bracket.
– Open clip -2- and pull off fuel return hose -1-.
lkswage es n
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byV ua
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tho
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– Open clip and pull off fuel supply line -arrow- from high pres‐
rm
ab
pe
sure pump.
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
– Unclip coolant hose bracket -1- by pushing it to one side.

a
com
tion in
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Prote AG.

Caddy 2011 ➤

– Remove fuel filter with bracket.
– Collect any escaping fuel. agen
AG. Volkswagen AG d
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spec
es, in part or in w
t to the co
rrectness of i
– Undo screw -arrow-. Place the filler neck for washer fluid res‐
l purpos
ervoir to one side.
nform
mercia
at
om
ion
c
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ate
do
priv
cum
for
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by c lksw
cted agen
– Press release buttons and remove hose -1- for venting crank‐ Prote AG.
case.
– Unscrew bolt -arrow- (captive bolt). Twist intake hose -A-

clockwise out of its holder and remove it.
– Remove cylinder head cover ⇒ page 109 .
1. Cylinder head 99
Caddy 2011 ➤
– Unclip vacuum lines -1- and -2-.

– Pull locking device to one side -arrow- and pull off changeover
valve for exhaust gas recirculation cooler - N345- -3- down‐
wards and place to one side.
– Pull off vacuum line -arrow-. AG. Volkswagen AG d

agen oes
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– Lay vacuum lines to side. byV
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ility
ot p
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spec
es, in part or in w
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– Unbolt connection of vacuum line -arrow-.
rrectness of i
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nf
ercia
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– Unclip engine pre-wiring harness from bracket -arrow-. C py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Pull off connector -2- from throttle valve module - J338- with
throttle valve potentiometer - G69- .
– Open clip -3- and pull off charge air hose.
– Unscrew bolt from oil dipstick connection -4-.
– Disconnect electrical connector -4- at coolant temperature

sender - G62- . agen
AG. Volkswagen AG d
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ility
ot p
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hole
spec
es, in part or in w
t to the co
– Separate electrical connector -1- on oil pressure switch - F1- .
– Undo screw -arrow-.
rrectness of i
– Pull off vacuum line -2- and place to one side.
l purpos
nform
mercia
at
om
ion
c
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ate
do
priv
cum
for
en
ng
t.
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– Remove bolts -2-, -5- and -arrows-.
Co
Cop py
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– Free electrical lines and hoses on left charge air pipe. yri
p by
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cted
– Loosen hose clip -3- and remove left charge air pipe.
agen
Prote AG.
1. Cylinder head 101

Caddy 2011 ➤
– Unscrew bolts -arrows- and remove pulsation damper -2-.

– Carefully push the charge air pipe to one side as far as pos‐
sible.
Caution
Ensure that flexible joint of connecting pipe is not bent and

stretched. There is a danger of cracking.
– Loosen particulate filter.
n AG. Volkswagen AG
– To create space for removing ksw and installing the oil supply
age does
not line
with turbocharger support, y Vol remove fastening clip -1- between
gu
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particulate filter and
ho
riseturbocharger. nte
e
t or
au ac
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an
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, is n
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hole
spec
es, in part or in w
– Unscrew bolt -1-. t to the co

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
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thi
s
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Cop py
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– Loosen securing nuts above particulate filter bracket -1- using
gh ht
pyri by
ring ratchet spanner - T10384- .
co Vo
by lksw
cted agen
Prote AG.
– Unscrew securing nuts -2- for particulate filter bracket on
crankcase.

Caddy 2011 ➤
– Now you can access the bolt of the retaining clamp -arrow- for
the oil return line on the turbocharger support. Undo screw
-arrow-.
– Remove connecting pipes -A- leading to cooler for exhaust

gas recirculation.
– Remove oil supply line and turbocharger support
⇒ page 180 .
– Remove coolant hoses from connections, loosen hose clips

-1- and -2- for this.
AG. Volkswagen AG d
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– Detach connector -arrow- for Hall sender - G40- .

an
d
itte
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ab

pe
ility
ot
wit
– Removing engine mounting ⇒ page 35 .

, is n
h re
hole
– Remove engine bracket ⇒ page 37 .

spec
es, in part or in w
– Removing toothed belt from camshaft and high-pressure

t to the co
pump ⇒ page 121 .

rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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en
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t.
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Cop py
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by
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103
Prote AG.
1. Cylinder head
AG. Volkswagen AG d
agen oes
olksw not
V
Caddy 2011 ➤ d by gu
ara
ise nte
4-cylinder diesel engine (1.6 l engine, common thorail)
r - Edition 09.2016 eo
au ra
ss c
– Unscrew bolt -arrow- of rear toothed belt guard.
ce
e
nl
pt
du
an
– Remove toothed belt tensioning roller.
itte
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erm
ab
– Install engine bracket again, tightening old bolts by hand
ility
ot p
⇒ page 37 .
wit
, is n
h re
– Install engine mounting again, tightening old bolts by hand
hole
spec
⇒ page 35 .
es, in part or in w
t to the co
– Remove support device - 10 - 222 A- .
– Remove camshaft sprocket from hub.
rrectness of i
l purpos
– Counterhold hub with counterhold - T10051- and release hub
nf
ercia
bolt -1-.
orm
m
– Unscrew hub bolt approx. 2 turns.
atio
om
n in
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thi
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Cop py
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pyri by
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co lksw
by
cted agen
Prote AG.
– Position puller - T10052- and align with hub holes.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft. Hold puller with 30 mm
spanner whilst doing this.
– Remove hub from taper of camshaft.

AG. Volkswagen AG d
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byV gu
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ed
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ut
ho Caddy
eo
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2011 ➤
a
4-cylinder
ss diesel engine (1.6 l engine, common rail) - Edition c 09.2016
ce
le
un
pt
– Observe correct sequence when loosening cylinder head
an
d
itte
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bolts.
rm
ab
pe
ility
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, is n
Note
h re
hole
spec
es, in part or in w
♦ A second mechanic is required to remove the cylinder head.
t to the co
♦ The toothed belt tensioning roller is pulled off the stud when
the cylinder head is lifted out.
rrectness of i
– First raise cylinder head on gearbox side and then thread it out
l purpos
of toothed belt guard. Make sure that toothed belt tensioner

does not fall down.
nform
mercia
Caution
a
com
tion in
r
te o
Risk of damage to glow plug pins -arrow- when cylinder head
thi
s
is being lowered.
iva
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cum
fo
♦ Do not lay removed cylinder head with installed glow plugs
en
ng
t.
down on sealing surface, as glow pins -arrow- project past op
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sealing surface.
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rig ht
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Prote AG.

Caddy 2011 ➤
Caution
Risk of damage to sealing surfaces!

♦ When using abrasive paper do not use a grade less than
100.
♦ Carefully remove any sealant residue from the cylinder
head and cylinder block. Ensure that no long scores or
scratches are made on the surfaces.
♦ Carefully remove remains of emery and abrasives.
Installing
Note
When renewing the engine/cylinder head, note that the plug in the
cylinder head must be renewed. This plug seals the oil passage
against the exterior.
Caution
Risk of damage to cylinder block!

♦ No oil or coolant may be contained in hole pockets for cyl‐
inder head bolts in cylinder block.
n AG. Volkswagen AG ge does
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Danger of cylinder head
by gasket leaks!
Vol
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♦ Do not remove ho new cylinder head gasket
r from packagingtee o
ut
until it is ready
ss
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♦ Handle the cylinder head gasket very carefully to prevent

nl
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gasket.
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Risk of damage to open valves.

wit
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♦ When installing an exchange cylinder head, the plastic

hole
spec
protectors fitted to protect the open valves should not be

es, in part or in w
removed until the cylinder head is ready to be fitted.

t to the co
Risk of damage to valves and piston crowns after working on

valve gear.
rrectness of i
♦ Turn the crankshaft carefully at least 2 rotations to ensure

l purpos
that none of the valves make contact when the starter is

operated.
nform
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om
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ate
do
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Prote AG.

Caddy 2011 ➤
Note
♦ Proceed with extreme caution. The assistance of a second

mechanic is vital.
♦ Always renew cylinder head bolts.
♦ Renew seals, gaskets, self-locking nuts, bolts tightened
through an additional specified angle and securing clamps.
♦ Do not remove new cylinder head gasket from packaging until
it is ready to be fitted.
♦ If an exchange cylinder head is installed, contact surfaces be‐
tween roller rocker fingers and running surface of cam must
be oiled.
♦ Tensioning roller must be pushed onto studs when fitting cyl‐
inder head.
♦ If the cylinder head gasket or cylinder head has been replaced,
select a new cylinder head gasket according to the number of
holes on the old cylinder head gasket.
♦ If parts of the crankshaft assembly have been renewed, the
new cylinder head gasket must be selected by measuring the
piston projection at “TDC” ⇒ page 80 .
swage es
– Before fitting cylinder
byV
olk head, remove crankshaftnostop t gu and turn
crankshaft ropposite
ise
d direction of rotation until all pistons
ara
nte are
nearly uniformly
utho below TDC. eo
ra
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ce
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– Note cylinder head gasket identification:

un
pt
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1- Part number
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2- Holes
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3- Ignore
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hole
spec
– Cylinder head gasket must lie with identification facing up‐

es, in part or in w
wards.
t to the co
– Before fitting cylinder head, remove crankshaft stop and turn

crankshaft opposite direction of rotation until all pistons are
rrectness of i
nearly uniformly below TDC.

l purpos
nform
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Prote AG.

Caddy 2011 ➤
– To centre, screw guide pins - 3070/9- into outer threaded holes

on intake side.
– Guide cylinder head into toothed belt guard and push tension‐
ing roller onto stud. When doing this, cylinder head must not
scrape over dowel sleeves -A-.
– Fit cylinder head.
– Insert 8 cylinder head bolts and screw in by hand until contact
is made.
– Unscrew guide pins - 3070/9- through bolt holes in cylinder
head and screw in remaining cylinder head bolts by hand as n AG. Volkswagen AG do
far as stop. olkswage es n
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– Tighten cylinder head in 4 stages in sequence shown as fol‐
e
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lows:
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ab
1- Tighten initially with torque wrench:
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Stage I = 35 Nm
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Step II = 60 Nm
spec
es, in part or in w
2- Turn further with rigid spanner:
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Stage III = turn 90° further.
rrectness of i
Stage IV = turn 90° further.
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– Install hub and camshaft pulley.

nform
ercia
– Install cylinder head cover ⇒ page 109 .

m
at
om
– Install oil supply line and turbocharger support ⇒ page 171 .

ion
c
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or
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ate
do
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Caddy 2011 ➤

bocharger. -arrow-.
– Install poly V-belt ⇒ page 48 .
– Top up engine oil ⇒ page 165 .
Do the following after any work on the fuel system:
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Using ⇒ Vehicle
orise diagnostic tester, carry out function nt“Fill/bleed
ee
high-pressure
aut
h pump/fuel system” ⇒ page 257 . or
ac
ss
– Carry out road test and read all event memories ⇒ Vehicle
ce
le
un
pt
diagnostic tester.
an
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Torque settings
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 88
wit
is n
h re
ole,
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 91
spec
t to the co
1.4 Removing and installing cylinder head
rrectne
cover
s
s o
cial p
♦ Pliers - 3314-
inform
mer
atio
om
n
c
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or
n thi
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Cop py
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Prote AG.

Caddy 2011 ➤
♦ Socket - T40055-
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Removing
h re
ole,
spec
Note safety precautions ⇒ page 1 .
t to the co
Observe rules for cleanliness ⇒ page 8 .
Observe instructions for working on fuel system ⇒ page 5 .
rrectne
– Remove noise insulation at injectors.
– Remove injectors ⇒ page 279 .
ss o
cial p
f inform
Caution
mer
atio
m
Make sure that no wiring connections are damaged when dis‐

o
n
c
i
or
n
connecting the connectors. Otherwise the whole wiring har‐
thi
e
ness will need to be renewed. Do not compress the pliers -

t
sd
iva
o
3314- to firmly to separate the connectors, otherwise the
pr
cum
r
fo
support sleeve may be damaged.
en
ng
t.
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Cop py
t. rig
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yri
– Position pliers - 3314- with groove -arrow A- on support sleeve p by
co Vo
shoulder -arrow B-.
by lksw
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Prote AG.
– Carefully pull connector off glow plug in -direction of arrow-.

Caddy 2011 ➤
– Open heat shield gaiter -1- from charge pressure servo posi‐
tion sender - G581- -3-.
– Disconnect and pull off electrical connector -2- on charge
pressure servo position sender - G581- -3-.
– Remove bolts -arrow-. Place coolant return line to one side. agen
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es, in part or in w
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G450- .
rrectness of i
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nf
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orm
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n in
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Cop py
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– Unscrew bolts from intake manifold -arrows-. Place fuel return

line to one side.

AG. Volkswagen AG d
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Caddy 2011 ➤ Vol
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rised common rail) - Edition 09.2016 ran
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tho or
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– Remove bolts for sealing flange -3-ss+ -4-, remove lifting eye
⇒ Item 10 (page 49) .
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e
nl
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Unscrew union nuts -1- and -3- with socket - T40055- .
nf
ercia
orm
m
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om
n in
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Prote AG.
– Open clip -arrow- and pull off line from high pressure accu‐
mulator.

Caddy 2011 ➤
– Disconnect connector from fuel pressure regulating valve -

N276- -arrow-. agen
AG. Volkswagen AG d
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olks ot g
– Remove cable guide from high pressure
ed
by accumulator and
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ran
place to one side. ho
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t or
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ss
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e
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an
itte
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spec
es, in part or in w
t to the co
– Detach connector from fuel pressure sender - G247- -B-.
– Remove high pressure accumulator.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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– Pull vacuum hose -A- off cylinder head cover.
Co
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– Remove other vacuum lines from bracket on cylinder head rig ht
py by
cover.
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– Remove remaining electric cables/wires.
– Remove upper toothed belt guard.
– Remove breather line between cylinder head cover and intake
hose. Press plug-in connectors together to do this.
– Undo and remove bolts -1- to -6- of cylinder head cover.

– Remove cylinder head cover.

Caddy 2011 ➤
– Unclip cylinder head cover at the locking lugs -arrows- on rear

toothed belt guard.
Installing
Note
♦ Renew seal for bolts if damaged.

♦ For clarity of illustration, the camshaft sprocket is not shown.
– Ensure that cylinder head cover is correctly clipped to toothed

belt guard.
– To do this, press toothed belt guard (using a screwdriver if

necessary) against cylinder head cover in area of clips
-arrows- until clips audibly engage in each other.
– Check clearance between hub and toothed belt guard.
– Screw bolts into cylinder head cover in the sequence -1- to
-6-.
– Tighten bolts in the sequence -1- to -6-. AG. Volkswagen AG d

agen oes
olksw not
After completing any work on the fuel system,d by V connect ⇒ Vehicle gu
ara
diagnostic tester, and perform functionoris“Bleed
e fuel system” nte
eo
⇒ page 257 . auth
ra
ss c
Torque settings
ce
le
un
pt
an
d

itte
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erm
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ility
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spec
t to the co
1.5 Removing and installing injector seals

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
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pyri by
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Prote AG.

Caddy 2011 ➤

equipment required
♦ Assembly tool - T10208/2-
♦ Lambda probe open ring
spanner set - 3337-
♦ Tool set - T10055-
♦ Seal puller - T 40195-
50 Nm) - V.A.G 1331-
♦ Tool set - T10133-
lkswage es n
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un
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spec
t to the co
♦ Injector remover - T10402-

rrectness o
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f inform
mer
atio
om
n
c
i
or
n thi
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sd
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pr
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t.
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Cop py
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Removing
c by lksw
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Prote AG.
– Remove only injectors (piezo injectors) whose injector seal is
to be renewed ⇒ page 279 .
– Move affected return lines slightly aside.

Caddy 2011 ➤
Caution
You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
Maintain cleanliness. No dirt must be allowed to get into the
disconnected fuel return lines or the open connections on the
injectors (piezo injectors).
First remove leaked oil or fuel with workshop equipment.
– Fit puller - T10055- with injector puller - T10402- -1- and -2-
as shown in illustration. Pull injectors out upwards by tapping
gently.
– Screw oil seal extractor - T40195- forcibly as far as possible
into seal by hand.
AG. Volkswagen AG d
agen oes
olksw not
V
Pull injector seal upwards by tapping gently using oiledseal
by extrac‐ gu
ara
tor - T40195- , adapter - T101333/2- and slide hammer
horis - nte
eo
T10133/3- . s aut ra
c
s
– After removal, check whether the spring washer is still on the
ce
le
un
pt
old seal.
an
d
itte
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rm
ab
If not, check that spring washer does not remain in injector shaft.
pe
ility
ot
Installing
wit
, is n
h re
hole

spec
es, in part or in w
t to the co
Caution

rrectness of i

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A plastic cylinder head cover is damaged easily during repairs.

Check cylinder head cover for damage.
nform
mercia
a
com
tion in
– Initially position new injector seal by hand.

r
te o
thi
– Then carefully push new injector seal in as far as stop using

s
iva
do
assembly tool - T10208/2- .

r
rp
cum
fo
en
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Torque settings
n
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
1.6 Removing and installing vacuum pump
DANGER!
The vacuum pump may, under no circumstances, be disman‐

tled as the vacuum part could otherwise malfunction. This
would result in failure of the brake servo.
Removing
pipe ⇒ page 305 .
– Detach vacuum line -2- from vacuum pump -1-.
– Undo and remove bolts of charge air pipe ⇒ page 234 .
– Then push charge air pipe down slightly to gain access to rear
threaded connection of vacuum pump.
– Place cloths under vacuum pump -1-.
– Unscrew vacuum pump bolts -arrows-.

– Remove vacuum pump from cylinder head.
Installing
AG. Volkswagen AG d
agen oes
olksw not
Note d byV gu
ara
ise nte
or eo
th
♦ Ensure that vacuum pump coupling seats
s au properly in cam‐ ra
c
shaft. s
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e
nl
pt
du
♦ Vacuum pump has been correctly seated in camshaft if it is

an
itte
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lying completely against cylinder head.

erm
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ility
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♦ The seal must be renewed.

wit
, is n
h re
hole
– Install vacuum pump, and tighten securing bolts.

spec
es, in part or in w
t to the co
– Connect brake servo vacuum line -2- to vacuum pump -1-.

Torque settings
rrectness of i

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♦ ⇒ “6.1 Assembly overview - air filter housing”, page 305

nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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t.
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1.7 Checking compression Cop py
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rig ht
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Special tools and workshop equipment required co Vo
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Prote AG.

Caddy 2011 ➤
♦ Compression tester - V.A.G 1763-
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Sequence of operations ss
ce
le
un
• Engine oil temperature min. 80°C
pt
an
d
itte
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• Battery voltage at least 12.5 V.
rm
ab
pe
ility
– Disconnect electrical connector from fuel pressure regulating
ot
wit
, is n
valve - N 276- -arrow- on fuel rail.
h re
hole
spec
– Start engine briefly to reduce fuel pressure in fuel rail.
es, in part or in w
t to the co
– Remove glow plugs ⇒ page 354 .
rrectness of i
l purpos
– Screw in adapter - V.A.G 1763/8- in each place where glow

plugs were and connect compression tester - V.A.G 1763- .
nform
ercia
– Check compression using compression tester - V.A.G 1763- .

m
a
Using compression tester ⇒ operating instructions .
com
tion in
r
– Have a 2nd mechanic operate starter until tester shows no

te o
thi
further pressure increase.
s
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Compression pressures bar

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New 25.0 to 31.0
Cop py
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Wear limit yri
19.0
p by
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Maximum difference between cylinders 5.0 cted agen
Prote AG.
Assembling
Assembly is carried out in reverse sequence; note the following:
– Clear event memory of engine control unit ⇒ Vehicle diagnos‐
tic tester.

Caddy 2011 ➤
2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt drive”, page 119
⇒ “2.2 Removing and installing toothed belt”, page 121
2.1 Assembly overview - toothed belt drive
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing.
❑ Check for wear.
❑ Do not kink.
⇒ page 121
2 - Bolt
❑ 20 Nm +45°
3 - Camshaft sprocket
4 - Tensioning pulley
❑ To remove, remove en‐
gine bracket ⇒ page 32
5 - Bolt
❑ 100 Nm. wage
es n
olks ot g
6 - Hub byV ua
d ran
ir se tee
utho
or
⇒ page 137 ss
a ac
ce
le
7 - Stud
un
pt
an
d
itte
❑ 15 Nm.
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rm
ab
pe
ility
8 - Idler roller
ot
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9 - Bolts
h re
hole
spec

es, in part or in w
❑ Qty. 3
t to the co
❑ 20 Nm +45°
10 - Toothed belt pulley on
rrectness of i
high-pressure pump
l purpos
11 - Bolt
❑ 15 Nm.
nform
ercia
12 - Idler roller
m
a
com
tio
13 - Toothed belt guard

n in
r
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thi
❑ Rear
s
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14 - Bolt
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❑ 20 Nm.
n
t.
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Cop py
.
15 - Bolt
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Prote
❑ 10 Nm.
AG.
16 - Nut
❑ 20 Nm +45°
2. Toothed belt drive 119

Caddy 2011 ➤
17 - Bolt
❑ 50 Nm +90°
18 - Hub
19 - Nut
❑ 95 Nm.
20 - Coolant pump
Volkswagen AG
❑ Removing and installing ⇒ page 198swagen AG. does
k not
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21 - Bolt d by ara
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ris
❑ 15 Nm. autho eo
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22 - Stud
ce
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un
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❑ 15 Nm.
an
d
itte
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rm
ab
23 - Idler roller
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ility
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24 - Nut
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h re
❑ 20 Nm.
hole
spec
es, in part or in w
25 - Crankshaft pulley
t to the co
26 - Bolt
rrectness of i
❑ Do not additionally oil or grease the threads and shoulder
l purpos
❑ Turning further can be done in several stages.

❑ 180 Nm +135°
nform
ercia

m
a
com
t
❑ Top section
ion in
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te o

thi
s
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❑ Bottom section
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29 - Bolt
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❑ 9 Nm. C py
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30 - Belt pulley and vibration damper cop Vo
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❑ Can only be installed in one position, holes are offset. Prote AG.

31 - Bolt
❑ 10 Nm +90°
32 - Bolt
❑ 40 Nm +180°
33 - Engine support
34 - Bolt
❑ 9 Nm.
35 - Protective plate

Caddy 2011 ➤
Lower toothed belt guard
2.2 Removing and installing toothed belt

equipment required
♦ 2x diesel injection pump
locking pin - 3359- agen
AG. Volkswagen AG d
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♦ Crankshaft stop - T10050- ed byV gu
ara
ris nte
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♦ Retainer - T10172- aut
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ra
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♦ Angled screwdriver -
ce
le
un
T10264- pt
an
d
itte
♦ Locking tool - T10265- y li

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ility
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♦ Bit XZN 10 - T10385- wit

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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
sd
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en
ng
t.
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Cop py
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rig ht
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Prote AG.

Caddy 2011 ➤
♦ Angled screwdriver - T10409-
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an
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erm
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ole,
spec
t to the co
rrectness o
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f inform
mer
atio
om
Note
n
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i
or
n thi
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sd
a
2 versions of tensioning roller are fitted. They are not interchange‐

iv
o
pr
able. When performing adjusting measures, check first to see

um
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en
which tensioning roller is installed.

ng
t.
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Cop py
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122
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Rep. gr.15 - Cylinder head, valve gear Prote AG.
Caddy 2011 ➤
Observe different directions of rotation during tensioning

Features of tensioning roller A:
♦ Locking tool - T10265- required for installation.
♦ Check that tensioning roller is seated correctly in toothed belt
guard.
♦ Tension toothed belt by turning tensioning roller eccentric
»clockwise«
Features of tensioning roller B:
♦ Locking tool not required.
♦ Tensioning roller is not seated in toothed belt guard.
♦ Tension toothed belt by rotating tensioning roller eccentric
»anticlockwise«
Removing
Note
Adjustment work on toothed belts must be performed only on cold

engines, as the indicator position on the tensioning element varies
depending on the engine temperature.
– Disconnect battery with ignition switched off ⇒ Electrical sys‐

tem; Rep. gr. 27 ; Disconnecting and reconnecting battery .
– Remove poly V-belt ⇒ page 48 . AG. Volkswagen AG d
agen oes
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– Unscrew bolt -1-. rise nte
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– Push washer fluid reservoir filler pipe with filler
ss neck -2- to side. c
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♦ Disregard -item 3-.

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fuel filter removed. t to the co

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inform
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– Disconnect connector -3- on radiator outlet coolant tempera‐

ture sender - G83- .
– Unscrew nut -1- and bolt -2-.
– Move right coolant pipe along with connected hoses -arrows-
to side.
– Remove upper timing belt guard by detaching clips -arrows-.

– Remove front right lower wheel housing liner ⇒ General body
repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
– Remove vibration damper ⇒ page 64 .

Caddy 2011 ➤

– Remove lower toothed belt guard.
– Mark direction of rotation of toothed belt.
– Turn crankshaft by bolt for toothed belt sprocket until toothed
belt for camshaft is at “TDC”.
AG. Volkswagen AG d
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– Fix the hub in place with locking pin for diesel injection pump
du
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Note
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-Arrows- can be disregarded.
es, in part or in w
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Version A: lock crankshaft pulley with mark in position

m
at
– Lock crankshaft pulley in position with crankshaft stop -

om
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T10050- .
n
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• Marks on toothed belt pulley -2- and crankshaft stop - T10050-

at
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belt pulley only from the face side.
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For crankshaft pulleys with a mark, it is also possible to use

crankshaft stop - T10490- .
T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
holes of toothed belt pulley.
• Locking pin of crankshaft stop - T10490- must engage in hole
in sealing flange.

AG. Volkswagen AG d
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Caddy 2011 ➤ Vol
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Version B: lock crankshaft pulley without
ss mark in position
ce
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Note
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Use only the crankshaft stop - T10490- to lock crankshaft pulleys
wit
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without a mark in position.
h re
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spec
es, in part or in w
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T10490- .
• Pins of crankshaft stop - T10490- must engage in threaded
rrectness of i
holes of toothed belt pulley.
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• Locking pin of crankshaft stop - T10490- must engage in hole

in sealing flange.
nform
ercia
Continuation for all vehicles

m
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– Loosen bolts -arrows- approx. 90° for camshaft toothed belt
on
c
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pulley.
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– Loosen bolts -arrows- by approx. 90° using bit XZN 10 -

T10385- .
Tensioning roller A:
– Loosen securing nut of tensioning roller -1- and turn tensioning

roller eccentric using socket - T10264- counter-clockwise
-arrow- until tensioning roller can be locked with locking pin -
T10265- .

Caddy 2011 ➤
– Turn eccentric of tensioning roller clockwise -arrow- to stop.

Only hand-tighten nut -1-.
Tensioning roller B:
– Loosen securing nut of tensioning roller, rotate eccentric of

tensioning roller clockwise with socket - T10409- until tension‐ gen AG. Volkswagen AG d
ing roller is relieved of tension. The tensioner of the tensioning
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roller should now be in the 9 o'clock position approximately.
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– Re-tighten securing nut hand-tight. ho eo
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Continuation for both tensioning rollers
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Risk of irreparable damage if direction of rotation is reversed
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on previously used toothed belt.
ole,
spec
♦ Before removing toothed belt, mark direction of rotation
t to the co
with chalk or felt tipped pen for installation purposes.
rrectne
– Remove toothed belt first from idler pulley and then from re‐
maining toothed belt pulleys.
ss
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♦ The toothed belt may only be adjusted on cold engines, as the

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must be removed ⇒ page 32 .
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♦ Renew securing bolts for camshaft pulley and high-pressure
pump pulley.
• Tensioning roller must be locked with locking tool - T10265-

and secured to right stop.
• The crankshaft is locked with crankshaft stop - T10050- or
crankshaft stop - T10490- .

Caddy 2011 ➤
• Set tensioner of tensioning roller to 9 o'clock position.

• Secure tensioning roller with 2 - 4 Nm.
Volkswa
• The crankshaft is locked agwith
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.
stop
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Note
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If necessary, turn camshaft hub with counterhold - T10172- and
adapters - T10172/4- until camshaft can be secured in position.
s
To do this, hand-tighten at least one securing bolt -1-.
s o
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– Loosen the hand-tightened bolt again.
mer
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– Lock camshaft hub with diesel injection pump locking pin -

pr
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3359- . To do this, insert locking pin through outer free elon‐

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t.
gated hole into hole in cylinder head.
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Bolts -arrows- screwed in loosely.
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It should just be possible to turn camshaft toothed belt pulley cted agen
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without axial movement.
Note
If necessary, turn hub of high-pressure pump at bolt heads with

screwdriver until it can be secured in position.
Positioning hub of high-pressure pump

Caddy 2011 ➤
– Lock high-pressure pump hub with diesel injection pump lock‐

ing pin - 3359- . To do this, push locking pin into adjustment
hole outside toothed belt pulley.
Loosely tightened bolts -1-.
It should just be possible to turn high-pressure pump toothed belt
pulley without axial movement.
– Turn camshaft pulley -3- and toothed belt pulley of high-pres‐

sure pump -5- in their elongated holes clockwise to stop.
– Fit toothed belt in sequence described:
1- Crankshaft pulley
2- Tensioning pulley
3- Camshaft toothed belt pulley
4- Coolant pump toothed belt pulley
5- High-pressure pump toothed belt pulley
6- Idler roller
– Loosen tensioning roller nut and pull out locking pin - T10265- .
AG. Volkswagen AG d
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Ensure that tensioning roller is seated correctly in rear toothed
erm
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belt guard -arrow-.
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spec
t to the co
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– Screw eccentric of tensioning roller clockwise carefully using

s o
angled screwdriver - T10264- . Indicator -2- must be roughly

cial p
f in
past the centre of the gap in the base plate (corrects itself dur‐
form
mer
ing pretensioning).
atio
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Ensure that securing nut -1- does not turn as well.

o
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– Hold tensioning roller in this position and tighten securing nut

t
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of tensioning roller.
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Cop py
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ss rail) - Edition 09.2016 c
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un
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– Fit counterhold - T10172- as shown. Press counterhold -
an
d
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T10172- in -direction of arrow- and keep camshaft pulley in
rm
ab
pretensioning position.
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– In this position, first hand-tighten bolts -1- of camshaft pulley
h re
and of toothed belt pulley for high pressure pump and then
hole
spec
tighten to correct torque.
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Carefully turn eccentric of tensioning roller anticlockwise using

angle driver - T10409- . Indicator -2- must be roughly past the
m
a
com
ti
centre of the gap in the base plate (corrects itself during pre‐
on in
tensioning).
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rig ht
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Markings on tensioning element and tensioning roller -arrow- are

now almost aligned.
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position. Tighten tensioning roller
securing nut -1-.
– Fit counterhold - T10172- as shown. Press counterhold -

T10172- in -direction of arrow- and keep camshaft pulley in
pretensioning position.
– In this position, first hand-tighten bolts -1- of camshaft pulley
and of toothed belt pulley for high pressure pump and then
tighten to correct torque.

Caddy 2011 ➤
– First, tighten securing bolts -arrows- for camshaft pulley by

hand, and then tighten them to specified torque.
– First, tighten securing bolts of high-pressure pump pulley by

hand, and then tighten them to specified torque.
olksw
– Remove dieselswinjection
agen
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- 3359- and crank‐
shaft stopby-VT10050-
olk or crankshaft stop -nT10490-
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– Turnthocrankshaft
ri by bolt for toothed belt sprocket t2ee turns
or in en‐
gine's
s au direction of rotation until crankshaft is at a position
ac
shortly
s
before “TDC”.
ce
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un
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– Fit crankshaft stop - T10050- or crankshaft stop - T10490- on

an
d
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crankshaft pulley again.

rm
ab
pe
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– Turn crankshaft in direction of engine rotation until pin of

ot
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crankshaft stop engages in sealing flange whilst turning.

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
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te o
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Cop py
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pyri by
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by
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Prote AG.

Caddy 2011 ➤
Note
During the following checking procedure, only the camshaft and

crankshaft must be secured in position. It is very difficult to find
the securing position of the high-pressure pump hub again. A mi‐
nor deviation -arrow-, though, does not influence engine opera‐
tion.
– Check:
♦ Camshaft hub can be locked with locking pin - 3359- .
♦ Tensioning roller indicator is centred or maximum 5 mm to
right of base plate notch.
– If the hub of the camshaft can not be locked in position, pull
camshaft stop back until the lug exposes the hole.
– Turn crankshaft back to slightly before “TDC” by turning it in
the opposite direction of engine rotation.
– Now turn crankshaft slowly in direction of. Vengine
gen AG
olkswagerotation
n AG d until
camshaft hub can be locked in
ol swa
kposition.
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– After locking, loosen bolts
ris for toothed belt sprocket of cam‐ tee
tho
shaft. au or
ac
ss
A - pin of crankshaft stop - T10050- or crankshaft stop - T10490- ce
e
nl
pt
du
is to the left of hole: an

itte
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erm
– Turn crankshaft in engine direction of rotation until crankshaft ab

ility
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stop pin engages in sealing flange whilst turning. wit

, is n
h re
– Tighten bolts for camshaft toothed belt pulley.
hole
spec
B - pin of crankshaft stop - T10050- or crankshaft stop - T10490-

es, in part or in w
is to the right of hole:

t to the co
– First, turn crankshaft a little in direction opposite to engine's

direction of rotation.
rrectness of i
– Turn crankshaft in engine's direction of rotation again until

l purpos
crankshaft stop pin engages in sealing flange whilst turning.

– Tighten bolts for camshaft toothed belt pulley.
nf
ercia
or
– Remove locking pin - 3359- and crankshaft stop .

m
m
atio
om
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐

n in
or c
gine's direction of rotation until crankshaft is at a position

thi
te
sd
shortly before “TDC”.

iva
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rp
cu
– Repeat measurement.
o
m
f
en
ng
t.
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– If camshaft hub can be secured in position, tighten bolts as Cop py
t. rig
follows: opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Camshaft pulley: ⇒ Item 2 (page 119) Counterhold with coun‐

terhold - T10172- and adapters - T10172/4- .
♦ High-pressure pump pulley: ⇒ Item 9 (page 119) Counterhold
with counterhold - T10172- and adapters - T10172/8- .
– Install middle and lower toothed belt guards.
– Install vibration damper.
– Install poly V-belt.
– Install upper toothed belt guard.
♦ Ensure fuel hoses are seated correctly.
♦ Do not interchange supply line and return line (return line blue
or with blue marking, supply line white).
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liner .
AG. Volkswagen n AG do
ks wage es
– Install noiseyinsulation
Vol ⇒ General body repairs,
not
gu exterior; Rep.
gr. 66 ;risBody
ed b
- front; Noise insulation . ara
nt ee
tho or
Torque
s a settings
u ac
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nl
pt
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♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 32 y li

erm
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spec
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t to the co
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Cop py
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gh ht
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by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 134
⇒ “3.2 Removing and installing camshafts”, page 137
⇒ “3.3 Measuring axial play of camshaft”, page 144
⇒ “3.4 Measuring radial play of camshaft”,
gen AG
. Volkpage
swage145
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⇒ “3.5 Removing and installing
db
yV camshaft oil seal”, page 145
t gu
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ris tee
⇒ “3.6 Checking hydraulic
ut
ho compensation elements”, page 147 or
a ac
ss
⇒ “3.7 Removing and installing valve stem seals”, page 147
ce
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⇒ “3.8 Removing and installing valve stem seals with cylinder
itte
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head removed”, page 151
erm
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3.1 Assembly overview - valve gear
wit
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hole
spec
Caution
es, in part or in w
t to the co
valve gear.
rrectness of i
♦ Because hydraulic compensation elements have to settle,
l purpos
engine must not be started for approx. 30 minutes after

installing camshafts.
nform
ercia

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Cop py
Cylinder heads with cracks between the valve seats may be used ht. rig
rig ht
without reducing engine life, provided the cracks are small and no
py by
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more than 0.5 mm wide. Prote
cted AG.
agen

AG. Volkswagen AG d
agen oes
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gu Caddy 2011 ➤
ol not
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d by ara
4-cylinder diesel
oris engine (1.6 l engine, common rail) - Edition
e nte 09.2016
h eo
aut ra
c
1 - Valve ss
ce
e
nl
❑ Do not rework. Only lap‐
pt
du
an
itte
ping in is permitted.
y li
erm
ab
❑ Mark installation posi‐
ility
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tion for re-installation.
wit
, is n
h re
❑ Valve dimensions
hole
⇒ page 156
spec
es, in part or in w
❑ Checking valve guides
t to the co
⇒ page 155 .
2 - Cylinder head
rrectness of i
❑ See note ⇒ page 88 .
l purpos

⇒ page 93
nform
ercia
3 - Valve stem seal

m
❑ Renew with cylinder
at
om
io
head installed
n
c
in t
r
⇒ page 147
o
his
ate
❑ Renewing with cylinder
do
priv
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head removed
um
for
en
g
⇒ page 151 .
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t.
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4 - Valve springs
t. C rig
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5 - Valve spring plate
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Prote AG.
6 - Valve cotters
7 - Sealing cap
❑ Removing: With retain‐
ing frame installed,
pierce one side of cap
with an awl and pry out.
❑ Installing: Drive in with‐
out sealant using an ap‐
propriate thrust piece.
❑ Drive in depth 1 to 2 mm
8 - Sealing ring
9 - Exhaust camshaft
❑ Note various versions
❑ Exhaust camshaft with camshaft restraining wheel ⇒ page 136
❑ Exhaust camshaft without camshaft restraining wheel ⇒ page 136
❑ Measuring axial clearance of camshaft ⇒ page 144
❑ Measuring radial clearance of camshafts ⇒ page 145
10 - Bolt
❑ Sequence when loosening ⇒ page 136 .
❑ 10 Nm.
11 - Ladder frame
❑ With integrated camshaft bearings.
12 - Inlet camshaft
❑ Measuring axial clearance of camshaft ⇒ page 144
3. Valve gear 135

Caddy 2011 ➤
❑ Measuring radial clearance of camshafts ⇒ page 145
13 - Roller rocker fingers agen
AG. Volkswagen AG d
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❑ Mark installation position d byV gu
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❑ Do not interchange hor eo
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❑ Check roller bearing for ease
s of movement.
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❑ Oil contact surface un
pt
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14 - Retaining clip
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❑ For hydraulic compensation element.
h re
hole
spec
15 - Hydraulic compensation element
es, in part or in w
t to the co
❑ Mark installation position
❑ Lubricate contact surfaces before installing.
rrectness of i
l purpos
Exhaust camshaft with camshaft restraining wheel
nform
mercia
a
com
tion in
r
te o
thi
s
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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.
Exhaust camshaft without camshaft restraining wheel
Sequence when loosening support frame.

– Unscrew bolts of support frame in sequence -24…1-.

Caddy 2011 ➤
Retaining frame - specified torques and installation sequence

– First, tighten bolts of support frame hand-tight in sequence
-1….24-. agen
AG. Volkswagen AG d
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t to the co
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3.2 Removing and installing camshafts
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f inform
mer
atio
m

o
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equipment required
i
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sd
a
♦ Diesel injection pump lock‐

iv
o
pr
c
ing pin - 3359-
um
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fo
en
ng
t.
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Cop py
t. rig
♦ Puller - T10052-
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pyri by
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♦ Camshaft fitting tool - Prote
cted AG.
agen
T40094-
♦ Camshaft clamping tool -
T40095-
♦ Camshaft fitting tool -
T40096-
3. Valve gear 137

Caddy 2011 ➤
♦ Silicone adhesive sealant ⇒ Electronic parts catalogue (ET‐

KA)
Removing
AG. Volkswagen AG d
– Remove fuel filter. agen oes
olksw not
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by ara
– Removed toothed belt from camshaft and risehigh-pressure
d pump nte
⇒ page 121 . ut
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s a c
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ce
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nl
pt
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– Unscrew securing bolts -1- of camshaft sprocket.

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erm
ab
– Remove camshaft sprocket from hub.

ility
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wit
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hole
spec
es, in part or in w
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nf
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orm
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or c
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te
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t.
yi Co
Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Counterhold hub with counterhold - T10051- and loosen hub

securing bolt -1-.
– Unscrew hub securing bolt approx. 2 turns.
– Position puller - T10052- and align with hub holes.

– Tighten securing bolts -1-.
– Apply tension to hub by evenly tightening puller -2- until hub
separates from taper of camshaft.
Note
Hold puller with a spanner 30 mm whilst doing this.
– Remove hub from taper of camshaft.

– Remove vacuum pump ⇒ page 117 .
AG. Volkswagen AG d
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– Unscrew retaining frame securing bolts in sequence
d by V -24…1-. gu
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– Remove retaining frame. utho eo
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s
– Carefully remove camshafts.
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Installing
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Note
spec
es, in part or in w
Seal parting surface between retaining frame and cylinder head t to the co
using silicone adhesive sealant ⇒ Electronic parts catalogue
(ETKA) .
rrectness of i
l purpos
Caution
nform
ercia
The camshafts may be installed only with the camshaft fitting

tool - T40094- as described below. Otherwise the axial bear‐
m
a
com
ings in the retaining frame will be destroyed and the cylinder

ion in
head must be replaced.

r
te o
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s
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Make sure that no sealant residue gets into the cylinder head
do
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rp
or the bearings.
um
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t.
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Cop py
t. rig
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Prote AG.
3. Valve gear 139

Caddy 2011 ➤
– Remove sealant residue from cylinder block and retaining

frame using, for example, a plastic rotary brush.
– Clean sealing surfaces. They must be free of oil and grease.
– Oil running surfaces of both camshafts.
AG. Volkswagen AG d
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Prepare camshaft fitting tool
s a - T40094- as follows:
ut ra
c
s
– Bolt supports -T40094/9- and -T40094/10- (with -T40094/11- )
ce
e
nl
pt
du
to base plate as shown in illustration. Remove any bolted-on
an
itte
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supports here if necessary.
erm
ab
ility
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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
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ate
– Place support -T40094/1- in position -F- and support -

do
priv
T40094/2- in position -A-.

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t.
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Cop py
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Prote AG.

Caddy 2011 ➤
– Insert inlet camshaft into supports -T40094/1- and -

T40094/2- .
– Turn inlet camshaft so that it can be locked in “TDC” position
with locking ruler -arrow 1-.
• The indentation -arrow 2- for the cylinder head bolt must face
outwards.
AG. Volkswagen AG d
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– Insert exhaust camshaft into supports -T40094/9- and -
spec
T40094/10- .
es, in part or in w
t to the co
– Lock exhaust camshaft with cover -T40094/11- .
• The lug -1- of the cover must engage in the slot -2- in the cam‐
rrectness of i
shaft.
l purpos
Vehicles with camshaft tensioning wheel

– Place clamping tool -T40096/1- on teeth of exhaust camshaft
nform
ercia
in such a way that the two arms of the tool engage on the two
halves of the gear (one in each half, as shown in illustration).
m
at
om
ion
• The wider arm must engage in the wider gear half.
c
in t
or
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– Tighten clamping tool using knurled wheel so that faces of

a
do
riv
gear teeth are in alignment.

p
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for
en
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Continued for all vehicles

n
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– Slide inlet camshaft towards exhaust camshaft until teeth en‐
t. rig
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Prote AG.
– Place retaining frame -1- on camshafts.

• All camshaft bearings must be seated on the camshafts.
– Fit camshaft fitting tool - T40095- and fix camshafts in position
in retaining frame as shown in the illustration.
3. Valve gear 141

Caddy 2011 ➤
– Remove -T40094/11- cover.

2 mm).
– Apply sealant beads (approx. 2 to 3 mm wide), as shown in
diagram, to clean sealing surfaces of cylinder head.
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ility
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spec
Note
es, in part or in w
t to the co
♦ Observe use-by date of sealant.

♦ The sealant beads must not be thicker than specified, other‐
rrectness of i
wise excess sealant could enter the camshaft bearings.

l purpos
– Install new cap ⇒ Item 7 (page 135) flush on cylinder head.

nform
ercia
– Remove camshafts from camshaft fitting tool - T40095- to‐

gether with retaining frame and camshaft fitting tool - T40094- .
m
at
om
ion
– Carefully insert camshafts and retaining frame into cylinder

c
in t
or
head.
his
ate
do
priv
cum
for
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t.
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Cop py
t. rig
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Prote AG.

Caddy 2011 ➤
– First, tighten bolts of support frame hand-tight in sequence

-1….24-. en AG. V
olkswagen AG
ag does
ol ksw not
• The retaining frame should make contact
yV with the cylinder gu
db ara
head over the complete surface.
ris
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ut
– Tighten retaining frame bolts
ss
a to final torque in the sequence ra
c
-1…24-.
ce
e
nl
pt
du
an
– Remove camshaft fitting tool - T40095- and clamping tool - itte
y li
T40096/1- .
erm
ab
ility
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– Renew camshaft seal ⇒ page 145 .
wit
, is n
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hole
spec
Caution
es, in part or in w
t to the co
valve gear.
rrectness of i
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
l purpos
installing camshafts.
nform
ercia

m
operated.
at
om
ion
c
in t
or
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ate
– Fit hub on camshaft.
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– Tighten securing bolt -1- of hub. Use counter-hold tool -

n
t.
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op
T10051- to do this. C py
t. rig
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Prote AG.
– Push camshaft pulley onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
– Insert securing bolts -1- by hand without play to camshaft pul‐

ley.
3. Valve gear 143

Caddy 2011 ➤
– Lock hub with locking pin - 3359- .

– Install vacuum pump ⇒ page 117 .
– Install cylinder head cover ⇒ page 109 .
– Install fuel filter.
Torque settings
♦ ⇒ “3.1 Assembly overview - valve gear”, page 134
3.3 Measuring axial play of camshaft

♦ Universal dial gauge holder - VW 387-
AG. Volkswagen AG d
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♦ Dial gauge - VAS 6079- s au ra
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s
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pe
ility
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es, in part or in w
t to the co
rrectness of i
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nform
– Remove retaining frame ⇒ page 137 .

mercia
– Fasten dial gauge - VAS 6079- to cylinder head with universal

a
com
tio
dial gauge bracket - VW 387- as shown in the illustration.

n in
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– Set dial gauge to “0”.

s
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– Press camshaft away from dial gauge and read off value:
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Axial clearance of inlet and outlet camshafts:
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• Specification: 0.048 to 0.118 mm.
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• Wear limit: 0.17 mm. cted agen
Prote AG.

Caddy 2011 ➤
3.4 Measuring radial play of camshaft

AG. Volkswagen
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♦ Plastigage
rise
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tee
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Sequence
s au of operations ac
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– Remove roller rocker finger ⇒ page 137 .

nl
pt
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an
itte
– Remove bearing cap and clean crankshaft journal.
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ility
– Place a length of Plastigage corresponding to the width of the
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bearing on the journal to be measured or into the bearings.
, is n
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hole
• The Plastigage must lie in the middle of the bearing.
spec
es, in part or in w
– Fit retaining frame and tighten without rotating camshafts
t to the co
⇒ page 137 .
– Remove retaining frame again ⇒ page 136 .
rrectness of i
– Compare width of Plastigage with the measurement scale.
l purpos
Radial clearance: 0.035 to 0.085 mm.
nf
ercia
3.5 Removing and installing camshaft oil seal
orm
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or
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equipment required
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♦ Fitting tool - 10-203-

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♦ Seal puller - T10443-
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50 Nm) - V.A.G 1331-
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Prote AG.
200 Nm) - V.A.G 1332-
♦ Bolt M12 x 1.5 x 75
3. Valve gear 145

Caddy 2011 ➤
Removing
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 121 .
– Remove camshaft sprocket and hub ⇒ page 137 .
Caution
If turned too far anti-clockwise, the inner thrust plate becomes

detached from the pressure screw. In this case, the thrust plate
must be pushed back onto the pressure screw.
– Turn pressure screw of oil seal extractor anti-clockwise »very

carefully« until slight resistance can be felt.
AG. Volkswagen AG d
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The clamping sleeves of the oil seal extractor are horfitted
is
with grub nte
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screws. However, only one of these grub screws aut -arrow- effects ra
s c
clamping. The other is screwed tight. s
ce
le
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itte
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erm
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ility
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spec
t to the co
– Fit oil seal extractor as shown and screw in grub screw -A- to
clamp it in place.
rrectne
– Screw pressure screw -B- in until oil ring has been pulled out.
Installing
ss o
cial p
f inform
mer
atio
m
Note
o
n
c
i
or
n thi
e
The oil seal sealing lip must not be additionally oiled or greased.
t
sd
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pr
cum
r
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– Remove oil residues from crankshaft journal with a clean cloth.

en
ng
t.
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Cop py
t. rig
– Fit guide sleeve - 3240- onto camshaft as shown in illustration. gh ht
pyri by
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by c lksw
– Carefully slide oil seal -1- over guide sleeve onto camshaft. Prote
cted AG.
agen

Caddy 2011 ➤
– Press in oil seal with press piece of fitting tool - 10-203- and
bolt M12 × 1.5 x 75 as far as stop.
– Install camshaft sprocket and hub ⇒ page 137 .
Torque settings
♦ ⇒ “2.1 Assembly overview
gen AG
.-Vtoothed
olkswagenbelt
AG drive”, page 119
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au ra
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3.6 Checking hydraulic compensation ele‐

itte
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ab
ments
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spec
es, in part or in w
t to the co
Note
♦ The hydraulic compensation elements cannot be repaired.
rrectness of i
♦ Irregular valve noise during starting is normal.
l purpos
– Start engine and run until the radiator fan has switched on
nform
ercia
once.
m
– Increase engine speed to approx. 2500 rpm for 2 minutes. If

a
com
tio
necessary, perform road test.

n in
r
te o
thi
If the hydraulic compensation elements are still noisy, determine

s
iva
do
the defective compensation element as follows:

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rp
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fo

en
ng
t.
yi Co
op py
– Turn crankshaft by the bolt for the toothed belt wheel until cam
t. C rig
gh ht
of supporting element to be tested is facing upwards.
yri
p by
co Vo
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cted
– Press roller rocker finger downwards -arrow- to check clear‐
agen
Prote AG.
ance between cam and roller rocker finger.
– If a 0.20 mm feeler gauge can be inserted between cam and
roller rocker finger, renew hydraulic compensation element.
3.7 Removing and installing valve stem

seals
♦ Valve stem seal puller - 3364-
3. Valve gear 147

Caddy 2011 ➤
♦ Valve stem seal fitting tool - 3365-
♦ Dismantling and assembling device for valve cotters - VAS

5161 A-
AG. Volkswagen AG d
agen oes
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ility
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Removing
h re
ole,
– Remove all glow plugs ⇒ page 354 .
spec
– Remove camshafts ⇒ page 137 .
t to the co
– Remove roller rocker finger ⇒ Item 13 (page 136) . When doing
so, note the installation position.
rrectne
– Place guide plate - VAS 5161/23- onto cylinder head.
ss
– Secure guide plate on intake manifold side with knurled screw
o
cial p
f
- VAS 5161/12- and hand-tighten studs with M6 collarless nuts
-1-. inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
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Cop py
t. rig
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Vo
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cted agen
– Screw sealing bolts - VAS 5161/10- into the guide plate.
Prote AG.
– Screw adapter - VAS 5161/11- hand-tight into the relevant

glow plug thread.

Caddy 2011 ➤
AG. Vocommon
lkswagen rail) - Edition 09.2016
n AG do
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olks ot g
– Insert punch - VAS 5161/3- in the guide plate andeuse d b a plastic
y V ua
ran
hammer to knock loose the firmly seated valve oricotters.
s tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw attachment fork - VAS 5161/5- with ratchet piece -
VAS 5161/6- into guide plate .
l purpos
– Push spacer ring - VAS 5161/17- onto assembly cartridge -

VAS 5161/8- .
nform
ercia
– Connect adapter - VAS 5161/11- to compressed air supply,

m
at
using a standard commercially available union and apply pres‐
om
io
sure continuously.
n
c
in t
or
his
e
• Minimum pressure: 6 bar.

at
do
priv
cum
– Attach pressure fork - VAS 5161/2- to ratchet piece and press
for
en
g
assembly cartridge downwards.

n
t.
yi Co
Cop py
– At the same time, turn knurled screw of assembly cartridge
t. rig
gh ht
yri
clockwise until tips engage in valve cotters.
p by
co Vo
by lksw
cted agen
– Move knurled screw backwards and forwards slightly. This
Prote AG.
causes the valve cotters to be pressed apart and taken into

the assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge with spacer ring, valve spring
plate and valve spring.
– Pull off valve stem seals using valve stem seal puller - 3364- .
Installing
3. Valve gear 149

Caddy 2011 ➤
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to

new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– If necessary, use a plastic head hammer to tap lightly on fitting
tool until valve stem oil seal is fitted to stop.
– Remove plastic sleeve.
– Insert valve spring and valve head into cylinder head.
n AG. Volkswagen A
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– If valve cotters have been removed from ed assembly cartridge ,
b ua
ran
they need to be put into insertion device
oris - VAS 5161/18- first. tee
th or
au ac
ss
ce
e
nl
pt
Note
du
an
itte
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erm
ab
Larger diameter of valve cotters faces upwards.
ility
ot p
wit
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h re
– Press assembly cartridge onto insertion device from above
hole
and pick up valve cotters.
spec
es, in part or in w
t to the co
rrectness of i
– Insert assembly cartridge - VAS 5161/8- into guide plate again.
l purpos
– Press pressure fork downwards and pull knurled screw up‐

wards, turning it clockwise and anticlockwise. This action will
install the valve cotters.
nform
ercia
– Reduce pressure on pressure fork whilst pulling on knurled

m
at
om
screw.
ion
c
in t
or
– Install camshafts ⇒ page 137 .

his
ate
do
riv
– Install glow plugs ⇒ page 354 .

p
cum
for
en
ng
t.
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Note t. C rig
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by c lksw
♦ Engine is not to be rotated for approx. 30 minutes after instal‐ Prote
cted AG.
agen
ling camshafts. The hydraulic compensation elements must
settle (otherwise valves will strike pistons).
♦ After working on the valve gear, turn the engine carefully at
least 2 rotations to ensure that none of the valves make con‐
tact when the starter is operated.
Torque settings

AG. Volkswagen AG d Caddy 2011 ➤
4-cylinder diesel agen (1.6 l engine,
engine common
oes rail) - Edition 09.2016
olksw not
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by ara
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ris
3.8 Removing and installing valve stem au
tho eo
ra
seals with cylinder head removed
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Valve stem seal puller - 3364-
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
m
♦ Valve stem seal fitting tool - 3365-

o
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or c
thi
te
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t.
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co Vo
by lksw
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Prote AG.
♦ Dismantling and assembling device for valve cotters - VAS

5161 A-
♦ Engine and gearbox support - VAS 6095A-
3. Valve gear 151

Caddy 2011 ➤
♦ Cylinder head tensioning device - VAS 6419-
Removing
– Remove camshafts ⇒ page 137 .
– Mark allocation of roller rocker fingers and hydraulic compen‐
sation elements for reinstallation.
– Remove roller rocker fingers together with hydraulic compen‐
sation elements and place down on a clean surface.
– Insert cylinder head tensioning device - VAS 6419- into engine
and gearbox support - VAS 6095A- .
Vo wagen AG lks
– Tension cylinder head on cylinder
swaghead
en AG.tensioning device
does as
shown in illustration. by
Volk not
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d ara
se nte
– Connect cylinder head
tho tensioning device to compressed air.
ri e or
u ac
sa
– Use lever -arrow- sto slide air cushion under combustion cham‐
ce
le
ber from which valve stem seal is to be removed.

un
pt
an
d
itte
– Allow compressed air to flow into air cushion until it lies against
y li
erm
ab
valve spring plate.

ility
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wit
is n
h re
ole,
spec
t to the co
– Place guide plate -VAS 5161/23- onto cylinder head.

rrectne
– Tighten guide plate on intake manifold side by hand using

knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
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.

Caddy 2011 ➤
– Insert drift -VAS 5161/3- into guide plate and use a plastic
hammer to knock loose the firmly seated valve cotters.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate. wage
e ks s no
Vol t gu
– Push sleeve -VAS 5161/23-1-ed onto assembly cartridge -
by ara
VAS 5161/8- . thoris nte
eo
au ra
– Attach pressure fork s-VAS
s 5161/2- to toothed piece and press c
ce
le
assembly cartridge down.

un
pt
an
d
itte
– At the same time, turn knurled screw of assembly cartridge
y li
rm
ab
clockwise until tips engage in valve cotters.
pe
ility
ot
wit
– Move knurled screw back and forth to press apart valve cotters
, is n
h re
and capture them in assembly cartridge.
hole
spec
– Release pressure fork.
es, in part or in w
t to the co
– Remove assembly cartridge together with spacer.
– Remove valve spring and valve spring plate.
rrectness of i
l purpos
– Pull off valve stem seal using valve stem seal puller - 3364- .
nform
ercia
Caution
m
a
com
Risk of damage when valve stem seals are being installed!

ion in
r
te o
thi
s
iva
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rp
cum
fo
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ng
t.
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Cop py
t. rig
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Vo
co lksw
by
cted agen
Prote AG.
Note
A plastic sleeve -A- is included with the new valve stem oil seals.
– Fit plastic sleeve -A- onto valve stem to prevent damage to

new valve stem oil seal -B-.
– Lightly oil sealing lip of valve stem seal.
– Push valve stem oil seal onto plastic sleeve.
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- .
– Remove plastic sleeve.
3. Valve gear 153

AG. Volkswagen AG d
agen oes
ksw not
Caddy 2011 ➤ by Vol
gu
ara
d
4-cylinder diesel engine (1.6 l engine, common orise rail) - Edition 09.2016 nte
eo
th
au ra
s c
– If valve cotters have been removed from assembly
s cartridge ,
ce
e
they need to be put into insertion device - VAS 5161/18- first.
nl
pt
du
an
itte
y li
• Larger diameter of valve cotters faces upwards.
erm
ab
ility
ot p
– Insert valve spring and valve spring plate.
wit
, is n
h re
– Press assembly cartridge onto valve cotter insertion device
hole
from above and pick up valve cotters.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Insert assembly cartridge - VAS 5161/8- into guide plate -

VAS 5161/23- again.
nf
ercia
orm
– Press pressure fork downwards and pull knurled screw up‐
m
atio
m
wards, turning it clockwise and anticlockwise. This inserts the

o
n in
c
valve cotters.
or
thi
te
sd
a
– Reduce pressure on pressure fork whilst pulling on knurled

iv
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screw.
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– Repeat procedure on each valve.
yi Co
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Installing
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Install in reverse order, noting the following: cted agen
Prote AG.
– Ensure that all roller rocker fingers contact valve stem ends
correctly and are clipped into relevant hydraulic compensation
elements.
– Install camshafts ⇒ page 137 .
Torque settings

AG. Volkswagen AG d
agen oes
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by Vol
gu
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Caddy 2011 ➤
d
orise 4-cylinder diesel engine (1.6
nte l engine,
eo
common rail) - Edition 09.2016
th
au ra
ss c
ce
4 Inlet and exhaust valves
le
un
pt
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⇒ “4.1 Reworking valve seats”, page 155
rm
ab
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⇒ “4.2 Checking valve guides”, page 155
ot
wit
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⇒ “4.3 Checking valves”, page 156
hole
spec
es, in part or in w
⇒ “4.4 Valve dimensions”, page 156
t to the co
4.1 Reworking valve seats
rrectness of i
Note
l purpos
Valve seats must not be reworked due to the very small toleran‐
nform
ercia
ces.
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4.2 Checking valve guides
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♦ Universal dial gauge holder - VW 387-
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Prote AG.
♦ Dial gauge - VAS 6079-
4. Inlet and exhaust valves 155

Caddy 2011 ➤
Note
♦ If the valve is to be renewed as part of a repair, use a new

valve for the measurement.
♦ Only insert inlet valve into inlet valve guide and exhaust valve
into exhaust valve guide, as the stem diameters are different.
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder head.
– Insert valve into valve guide.
• The end of the valve stem must be flush with the guide.
– Determine rock.
• Wear limit: 1.0 mm.
– If the wear limit is exceeded, repeat the measurement with
new valves.
– Renew cylinder head if wear limit is still exceeded.
Note
AG. Volkswagen AG d
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Valve guides cannot be exchanged. Volksw not
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4.3 Checking valves ss a c
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– Check for scoring on valve stems and valve seat surfaces.
an
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– Exchange valve if significant scoring can be seen.
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4.4 Valve dimensions

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es, in part or in w
Note t to the co
Inlet and exhaust valves must not be reworked. Only lapping-in

is permitted.
rrectness of i
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Dimension Inlet valve Outlet valve

∅a mm 26.50 to 26.70 24.4 to 24.60
nform
ercia
b mm 99.30 99.10
m
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Diameter mm 5.968 to 5.982 5.958 to 5.972

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Caddy 2011 ➤
AG. Volkswagen AG d
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17 – Lubrication byV gu
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1 Sump, oil pump
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⇒ “1.1 Assembly overview - sump/oil pump”, page 157
erm
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ility
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⇒ “1.2 Removing and installing oil sump”, page 159
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is n
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⇒ “1.3 Removing and installing oil pump”, page 163
ole,
spec
⇒ “1.4 Engine oil:”, page 165
t to the co
⇒ “1.5 Removing and installing oil level and oil temperature send‐
er G266 ”, page 165
rrectne
⇒ “1.6 Measuring oil consumption”, page 166
1.1 Assembly overview - sump/oil pump
ss o
cial p
f inform
1 - Bolt
mer
atio
m
❑ 15 Nm.
o
n
c
i
or
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2 - Sealing flange
thi
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❑ With seal
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❑ Must seat on dowel en

ng
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sleeves.
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.
❑ Insert with silicone seal‐
ht rig
rig ht
by
ant ⇒ Electronic parts copy Vo
by lksw
catalogue (ETKA) . cted agen
Prote AG.
grease the oil seal seal‐
ing lip.
❑ Before installing, re‐
move oil residue from
crankshaft journal using
a clean cloth.
❑ Renewing crankshaft oil
seal on belt pulley end
⇒ page 66 .
⇒ page 53
3 - Toothed belt for oil pump
❑ Check for damage and
wear.
❑ Renew if necessary.
Note
♦ Belts which have been in use

longer can sag.
♦ This is not a fault and does not
necessarily mean belt needs re‐
placing.
4 - Bolt
❑ 10 Nm.
5 - Oil dipstick
❑ The oil level must not be above the max. mark!
❑ Markings ⇒ page 165 .
1. Sump, oil pump 157

Caddy 2011 ➤
6 - Guide tube lkswage es n
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7- Fastener or is tee
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8- Dowel sleeves
ss
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9 - O-ring
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10 - Bolt
h re
hole
❑ 10 Nm.
spec
es, in part or in w
t to the co
11 - Oil pump with pressed-on toothed belt pulley
❑ With 12 bar pressure relief valve
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
rrectness of i
If toothed belt or oil pump have to be removed:
l purpos
♦ Check oil pump for free movement

♦ It should be possible to turn toothed belt sprocket easily with 1 finger.
nform
ercia
♦ Replace if difficult to turn.

m
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ion
12 - Suction line
c
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❑ Clean strainer if soiled

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13 - Baffle plate
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14 - Bolt
Co
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❑ 15 Nm.
t
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15 - Oil pan
by
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Prote AG.
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic parts catalogue (ETKA) .
16 - Bolt
17 - Fastener
❑ Only vehicles with cover for oil sump
❑ High
18 - Fastener
❑ Only vehicles with cover for oil sump
❑ Low
19 - Cover for oil sump
❑ Not fitted in all vehicles
20 - Bolt
❑ 10 Nm.
21 - Oil level and oil temperature sender - G266-
❑ 3-pin
22 - Sealing ring
23 - Oil level and oil temperature sender - G266- wiring harness
❑ Connector, black
24 - Oil drain plug
158 Rep. gr.17 - Lubrication

Caddy 2011 ➤
❑ 30 Nm.
25 - Sealing ring
26 - Bolt
❑ 15 Nm.
27 - Bolt
❑ Insert without sealant.
❑ 27 Nm.
28 - Oil spray jet
AG. Volkswagen AG d
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Sump - specified torque and tightening sequence
ised b ara
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– Tighten bolts in 3 stages: s aut ra
c
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stage Bolts Torque setting

un
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1st -1 to 20- In diagonal sequence to 5 Nm
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2nd -Arrows- 40 Nm.
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3rd -1 to 20- diagonally in stages; final torque
h re
13 Nm
hole
spec
es, in part or in w
t to the co
rrectness of i
1.2 Removing and installing oil sump
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ T-bar and socket, 10 mm - 3185-

Caddy 2011 ➤
Removing
– Drain engine oil ⇒ Maintenance ; Booklet 39 .
– Open clips -1- and -2- and remove connecting hose.
lkswage es n
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nl
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– Lay coolant hose -3- to one side.
es, in part or in w
t to the co
– Release hose clip -2-.
– Disconnect electrical connector -1- on charge pressure sender rrectness of i
- G31- and remove right air pipe.
l purpos
nf
ercia
orm
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Prote AG.
– Screw bolt out -arrow- and push coolant circulation pump 2 -
V178- to the side.

Caddy 2011 ➤
– Remove bolts -arrows- of charge air pipe.
olkswagen AG
en AG. V
– Disconnect electrical connector -arrow- on ooil level
lksw
ag and oil does
not
temperature sender - G266- . ed
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nl
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ility
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hole
spec
es, in part or in w
t to the co
– Remove noise insulation -1- for sump. To do this, open fas‐
rrectness of i
teners -arrows-.
l purpos
nf
ercia
orm
m
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om
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or c
thi
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sd
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– Remove connecting bolts for sump and gearbox. py by
co Vo
by lksw
cted
– Slacken bolts -1 … 20- in diagonal sequence and remove.
agen
Prote AG.
– Release oil sump carefully from adhesive.

– Loosen sump with light blows of a rubber headed hammer if
necessary.
– Remove sealant remaining on crankcase with flat scraper.

Caddy 2011 ➤
Installing
WARNING
Risk of eye injury!

♦ Wear safety goggles.
♦ Cover open parts of engine.
– Remove sealant residue from bottom section of sump -1- us‐

ing a rotating plastic brush, for example.
• Make sure to not damage the surface coating of the bottom
section of sump.
• Sealing surfaces must be free of grease and oil.
Use sealant as per ⇒ Electronic parts catalogue (ETKA) .
Note
Observe use-by date of sealant.

3 mm).
AG. Volkswagen AG d
agen oes
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spec
t to the co
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cial p
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mer
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c
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te
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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Apply bead of sealant onto clean sealing surface of sump as

illustrated.
• Thickness of sealant bead: 2…3 mm.
Note
♦ Do not apply sealant bead thicker than specified.

♦ Take particular care when applying sealant bead -arrows- in
area of rear sealing flange.
♦ The sump must be installed within 5 minutes after sealant is
applied.
♦ When installing sump with engine removed, ensure that sump
is flush with crankcase at flywheel end.
AG. Volkswagen AG d
♦ Let sealing compound dry for approx. 30 minutes
lksw after instal‐
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ling oil sump. Only then fill with engine oil. db
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– Place oil sump in position and slightlyau tighten the sump--to- ra
c
ss
gearbox connecting bolts and all the oil sump bolts. Ensure
ce
e
nl
that sump is flush against intermediate plate and gearbox
pt
du
an
flange.
itte
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ab
– Install coolant circulation pump 2 - V178- .
ility
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– Install air pipes ⇒ page 234 .
h re
hole
spec
– Installing intake hoses with screw-type clips ⇒ page 235 .
es, in part or in w
t to the co
– Replenish engine oil and check oil level ⇒ Maintenance ;
rrectness of i
Booklet 39 .
l purpos
Torque settings
nf
ercia
orm
m
1.3 Removing and installing oil pump atio

om
n in
or c
thi
Removing
te
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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.

Caddy 2011 ➤
– When oil pump is to be renewed, unscrew bolts -4- and remove

oil intake pipe -3-.
– Unscrew bolts -arrows- and remove baffle -2-.
. Volkswagen AG
gen AG does
– Detach oil pump -1- from toothed belt and remove
Vol
kspump.
wa not
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– Check oil pump for ease of movement, turnoristoothed
e belt pulley nte
with one finger for this. auth eo
ra
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nl
pt
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Note
an
itte
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ab
ility
♦ If oil pump does not move easily, it must be renewed.
ot p
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♦ A damaged toothed belt must be renewed.
h re
hole
spec
♦ The toothed belt can sag after long use, this is not a fault.
es, in part or in w
t to the co
– Check toothed belt for oil pump.
Installing
rrectness of i
l purpos
– Renew O-ring.
nf
ercia
or
– Insert new dowel sleeves when oil pump has no dowel sleeves
m
m
atio
-arrows- for centring oil pump.
om
n in
or c
– Fit oil pump with toothed belt pulley into toothed belt and tight‐
thi
te
en along with baffle.
sd
iva
o
r
rp
cu
– Install sump ⇒ page 159 .
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f
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ng
t.
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– Replenish engine oil and check oil level ⇒ page 165 . t. Cop py
rig
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Torque settings p by
co Vo
by lksw
cted agen
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 157 Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
d byV gu
ara Caddy 2011 ➤
e
4-cylinder
oris diesel engine (1.6 l engine, common rail)
nte - Edition 09.2016
e
th or
au ac
ss
1.4 Engine oil:
ce
le
un
pt
an
d
itte
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rm
ab
Note
pe
ility
ot
wit
, is n
h re
The oil level may be in area -d- due to the infiltration of fuel in the
hole
engine oil as a result of unfavourable driving conditions after fill‐
spec
ing. This is normal and regulates itself automatically. No engine
es, in part or in w
t to the co
oil needs to be drained.
1 - Min. mark
rrectness of i
2 - Max. mark
l purpos
a - Oil level in min. mark area: replenish engine oil!
nform
ercia
b - Oil level in middle range: can be topped-up with engine oil.

m
a
c - Oil level in max. mark area: Do not replenish engine oil!
com
tion in
r
d - The oil level may be in this area as a result of particular driving

te o
thi
conditions.
s
iva
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Note
Co
Cop py
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rig ht
The oil level must remain below the max. mark - danger of dam‐
py by
co Vo
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age to catalytic converter! Markings Prote
cted AG.
agen
Oil capacities
With oil filter change: 4.3 l
Without oil filter change: 4.0 l
1.5 Removing and installing oil level and oil

temperature sender - G266-
Removing
– Drain engine oil.
– Disconnect electrical connector -arrow- on oil level and oil
temperature sender - G266- .
– If fitted, remove noise insulation -1- for sump. To do this, loos‐

en retaining elements -arrows-.

Caddy 2011 ➤
– Unscrew bolts -2-.

– Remove oil level and oil temperature sender - G266- -1-.
Installing
– Replenish engine oil and check oil level ⇒ Maintenance ;
Booklet 39 .
Torque settings
1.6 Measuring oil consumption

wage
e ks s no
Vol t gu
Special tools and workshop equipmentedrequired
by ara
ris nte
♦ Vehicle diagnostic tester utho eo
ra
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ss
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– Apply handbrake.
itte
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ab
– Manual gearbox: gear lever in neutral.
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wit
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– Automatic gearbox: move selector lever to position “N”.
h re
ole,
spec
– Connect ⇒ Vehicle diagnostic tester.
– Switch on ignition. t to the co
– Carry out program “oil consumption measurement” using

⇒ Vehicle diagnostic tester.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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cum
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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
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
2 Engine oil cooler

⇒ “2.1 Removing and installing engine oil cooler”, page 167
2.1 Removing and installing engine oil cool‐

er
♦ Used oil collection and extraction unit - V.A.G 1782-
lkswage es n
o ot g
byV ua
d ran
ir se tee
♦ Drip tray for workshop hoist - VAS 6208- utho
or
a ac
ss
ce
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nl
pt
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erm
ab
ility
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es, in part or in w
t to the co
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nform
mercia
at
om
ion
c
in t
or
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ate
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for
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t.
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t. rig
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pyri by
Vo
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by
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Prote AG.
2. Engine oil cooler 167

Caddy 2011 ➤
Removing
– Open air intake cover. To do this, carefully release the catches
-arrows-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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ce
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un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
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h re
hole
spec
– Unscrew bolts -arrows- for air intake -1- and take connecting
es, in part or in w
hose -2- out of guide.
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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c
– Press in locking lugs -1- and -3- and pull connecting hose -4-
um
fo
en
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off air filter housing -2-.

n
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ht ht
rig by
py Vo
– Remove radiator cowl ⇒ page 208 .
co lksw
by
cted agen
Prote AG.
– In addition to draining coolant from engine, pull coolant hose

from oil filter holder -arrow-.

Caddy 2011 ➤
– Remove oil filter element.
AG. Volkswagen AG d
agen oes
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un
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rm
ab
pe
ility
ot
wit
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h re
hole
spec
– Remove engine oil cooler from housing.
es, in part or in w
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia
♦ Renew gaskets, seals and O-rings.

m
com
tion in

r
te o
thi
s
iva
do
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rp
cum
– Insert new seals ⇒ Item 11 (page 172) into oil free lugs
fo
en
g
-arrow- on oil filter bracket.

n
t.
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Cop py
– Carefully slide engine oil cooler onto centring pins.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Press on oil cooler until it is flush -1- with end of centring pins.
– Start new bolts, and screw them in until heads make contact.
2. Engine oil cooler 169

Caddy 2011 ➤
. Volkswagen AG
a gen AG does
– Tighten bolts -arrows- alternately in diagonal
Vol
ksw sequence in 3 not
gu
steps. e d by ara
nte
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– Install oil filter element, replenish
auth
engine oil and check oil level. ra
ss c
– Replenish coolant in cooling system, change coolant if engine
ce
le
un
pt
oil cooler has been renewed ⇒ page 187 .
an
d
itte
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erm
Torque settings
ab
ility
ot p
♦ ⇒ “3.1 Assembly overview - oil filter housing with engine oil
wit
is n
cooler”, page 171
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
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pr
cum
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fo
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ng
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 ➤
3 Oil filter, oil pressure switch

⇒ “3.1 Assembly overview - oil filter housing with engine oil cool‐
er”, page 171
⇒ “3.2 Removing and installing oil filter housing”, page 172
⇒ “3.3 Removing and installing oil pressure switch F1 ”,
page 175
⇒ “3.4 Checking oil pressure switch”, page 177
⇒ “3.5 Checking oil pressure”, page 178
3.1 Assembly overview - oil filter housing

with engine oil cooler n AG. Volkswagen A G do
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Caution ris
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Seals ⇒ Item 11 (page 172) and must ⇒ssItem 14 (page 172)
not be lubricated with oil. The coolant seals would otherwise
ce
e
nl
pt
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swell up.
an
itte
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erm
ab
ility
ot p
wit
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1 - O-ring
hole
spec
es, in part or in w
t to the co
2 - Sealing cap
❑ 25 Nm.
rrectness of i
3 - O-ring
l purpos

4 - O-ring
nf
ercia
o
rm
m
atio
m
5 - Oil filter element

o
n in
or c
❑ Observe general notes

thi
e
on the lubrication sys‐

t
sd
iva
tem ⇒ page 5
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rp
cu
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f
❑ Observe change inter‐

en
ng
t.
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vals ⇒ Maintenance ; Cop py
Booklet 39 ; Proce‐
t. rig
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p by
co Vo
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6 - Guide tube
Prote AG.
❑ Renew O-ring after

each removal
7 - Bolt
❑ 10 Nm.
8 - Fastener
9 - Engine oil cooler
❑ Ensure clearance to ad‐
jacent components
❑ Renew coolant after re‐
placing
❑ Observe general notes
on the lubrication sys‐
tem ⇒ page 5 .
❑ Connection diagram for
coolant hoses ⇒ page 186
3. Oil filter, oil pressure switch 171

Caddy 2011 ➤
❑ Checking engine oil cooler for leaks ⇒ page 186 gen AG. Volkswagen AG
wa does
❑ Removing and installing ⇒ page 172 olks not
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10 - Bolt thoris e or
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❑ Initial specified torque: 5 Nm ss
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❑ 11 Nm.
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11 - Rubber seals
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ility
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❑ Insert into lugs on engine oil cooler.
h re
hole
❑ May not be lubricated with oil
spec
es, in part or in w
12 - Bolt
t to the co
❑ First, start upper left and lower right bolts.
rrectness of i
❑ Tightening sequence ⇒ page 172
l purpos
❑ 14 Nm +180°
13 - Oil filter bracket
nf
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❑ Ensure clearance to adjacent components
rm
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❑ With integrated oil non-return

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14 - Rubber seals
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❑ Fit into lugs on oil filter bracket. t. Cop py
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❑ May not be lubricated with oil
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Prote AG.
Tightening sequence for oil filter bracket
3.2 Removing and installing oil filter housing


Caddy 2011 ➤
AG. Volkswagen AG d
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nl
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es, in part or in w
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ate
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Cop py
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Prote AG.
Removing
– Remove radiator cowl ⇒ page 208 .

Caddy 2011 ➤
– Remove oil filter element.

Instructions for hose connections ⇒ page 235 AG. Volkswagen AG d
agen oes
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spec
t to the co
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– Loosen hose clamps -1- and -2- and remove air hose.
form
mer
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n
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Cop py
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rig ht
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by lksw
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Prote AG.

– Disconnect electrical connection -1- on charge pressure send‐
er - G31- / intake air temperature sensor - G42- and remove
right charge air pipe.

Caddy 2011 ➤
– Pull out oil dipstick slightly, unscrew bolt -1-.

– Press off clip -2- using removal lever - 80 - 200- .
– Pull oil dipstick guide tube off cylinder block upwards and push
to side. gen AG
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d wa oes
olks not
– Place drip tray for workshop hoist - VAS
db
y V 6208- under coupling gu
ara
point. orise nte
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– Remove coolant hose -4-, loosening hose clip -3- to do so.
l purpos
– Place used oil collection and extraction unit - V.A.G 1782- un‐
der engine.
nform
ercia
– Unscrew bolts -2- and remove oil filter bracket together with
m
a
com
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engine oil cooler.
ion in
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Installing
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♦ Renew gaskets, seals and O-rings. cted agen
Prote AG.
– Install dipstick guide tube ⇒ page 171 .

– Install charge air pipe ⇒ page 234 .
– Install radiator cowl ⇒ page 208 .
– Install oil filter element, replenish engine oil and check oil level
⇒ Maintenance ; Booklet 39 .
– Replenish coolant in cooling system, change coolant if engine
oil cooler has been renewed ⇒ page 187 .
Torque settings
♦ ⇒ “3.1 Assembly overview - oil filter housing with engine oil
cooler”, page 171
3.3 Removing and installing oil pressure

switch - F1-

Caddy 2011 ➤
AG. Volkswagen AG d
agen
♦ Hose clamp pliers - VAS 6340- Volksw
oes
not
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t to the co
Removing
rrectne
– Remove hose -1- for crankcase breather system. To do this,
press the release buttons.
ss o
cial p
f
– Move clear vacuum hoses -arrows-.
inform
mer
– Release hose clips -3- and pull air hose off air filter housing.
atio
om
– Unscrew bolt -2-, swing intake hose with intake connection to

c
i
or
rear and pull off of turbocharger.

thi
te
sd
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pr
cum
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t.
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Cop py
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Prote AG.
– Unscrew bolts -2- and -3-, remove engine lifting eyes -1-.
– Separate electrical connector -arrow-.
– Remove oil pressure switch - F1- .
Installing
– Install vacuum line to exhaust gas recirculation cooler.
– Install intake connection.

Caddy 2011 ➤

bocharger. -arrow-.
Torque settings
3.4 Checking oil pressure switch AG. Volkswagen AG d

agen oes
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Special tools and workshop orised
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equipment required aut
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♦ Oil pressure tester - V.A.G
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1342-
an
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♦ Voltage tester - V.A.G
erm
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ility
1527 B-
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♦ Adapter set - V.A.G
h re
ole,
1594 C-
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
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sd
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pr
cum
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fo
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
Checking oil pressure switch - F1-

Test conditions
• Oil level OK, checking ⇒ page 165
• Engine oil temperature at least 80°C (radiator fan must have
run once)

Caddy 2011 ➤
Test sequence
Note
Functional check and repair of the optical and acoustic oil pres‐
sure warning: ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations
– Remove oil pressure switch - F1- ⇒ page 175 .

– Screw oil pressure switch - F1- -2- into oil pressure tester -
V.A.G 1342- .
– Remove oil pressure switch - F1- -2- and screw into oil pres‐
sure tester - V.A.G 1342- .
– Connect brown line -1- of oil pressure tester to earth (–).
– Connect voltage tester - V.A.G 1527B- to battery positive (+)
and oil pressure switch - V.A.G 1594C- using auxiliary cable
from auxiliary measuring set - F1- .
• LED should not light up.
If the LED lights up:
– Replace oil pressure switch - F1-
If LED does not light up:
Note
olkswagen AG
en AG. V
Observe oil pressure tester and LED while starting, as switching ksw
ag does
not
Vol
point of oil pressure switch - F1- may already be exceeded when ed by gu
ara
starting. ho
ris nte
eo
t
au ra
c
ss
– Start engine and slowly increase engine speed.
ce
le
un
pt
an
d
• From 0.30 to 0.60 bar upwards, the LED must light up, other‐
itte
y li
wise renew oil pressure switch - F1- ⇒ page 175 .
erm
ab
ility
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Torque settings
wit
is n
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ole,
spec
t to the co
3.5 Checking oil pressure
rrectne
♦ Oil pressure tester - V.A.G 1342-
ss o
cial p
f inform
mer
atio
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n
c
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Cop py
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Test conditions
Prote AG.
• Oil level OK, checking ⇒ page 165 .

Caddy 2011 ➤
• Engine oil temperature at least 80°C (radiator fan must have

run once)
Test sequence
– Remove oil pressure switch - F1- ⇒ page 175 .
– Connect oil pressure tester - V.A.G 1342- to hole for oil pres‐
sure switch - F1- .
– Screw an old oil pressure switch into hole on oil pressure tester
- V.A.G 1342- to seal hole.
– Start the engine.
• Oil pressure at idling speed: at least 0.6 bar
• Minimum oil pressure at 2,000 rpm: at least 1.0 bar
AG. Volkswagen AG d
agen oes
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Prote AG.

Caddy 2011 ➤
AG. Volkswagen AG d
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4 Oil circuit yV
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ut
⇒ “4.1 Assembly overview - oil circuit”, page 180 ss a ra
c
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⇒ “4.2 Removing and installing oil supply line”, page 180
un
pt
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4.1 Assembly overview - oil circuit
rm
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ility
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1 - Bolt
hole
spec
❑ 20 Nm.
es, in part or in w
t to the co
2 - Oil supply line
⇒ page 180
rrectness of i
3 - Oil return line
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❑ Renew seal after each

removal
nform
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4 - Bolt
m
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com
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❑ 22 Nm.
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5 - Bolt
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❑ 22 Nm.
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6 - Connection pipe to exhaust
C py
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gas recirculation cooler rig ht
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lksw
❑ Renew seals after each
by
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Prote
removal
AG.
7 - Bolt
❑ 10 Nm.
8 - Support
❑ For turbocharger
9 - Banjo bolt
❑ 60 Nm.
10 - Banjo bolt
❑ Renew seals after each
removal
❑ 30 Nm.
11 - Bolt
❑ 9 Nm.
4.2 Removing and installing oil supply line


Caddy 2011 ➤
♦ Torque wrench - V.A.G 1331- .
lkswage es n
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♦ Tool set - T10395- ss
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rm
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
mercia
a
com
tion in
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te o
thi
s
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t.
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Cop py
t. rig
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pyri by
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by
cted agen
Prote AG.
Removing
– Unscrew bolts -1- and remove axle shaft shield.
Loosen particulate filter.
to create space for removing and installing the oil supply line with
turbocharger support.
4. Oil circuit 181

Caddy 2011 ➤
– Disconnect connector at exhaust gas pressure sensor 1 -

G450- -2- and unscrew securing bolt -3-.
– Remove bolt -4- and pull exhaust gas pressure gesensor
n AG. Vol1 -
kswagen AG
does
swa
G450- off bracket -arrow-. yV
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th or
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spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
bocharger.
m
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com
tion in
r
te o
thi
s
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cum
fo
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ng
t.
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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 ➤
– Unscrew nuts -2-.
Caution
Avoid damage to the flexible joint!

♦ Do not bend de-coupling element in front exhaust pipe by
more than 10°.
lkswage es n
o ot g
– Place particulate efilter
d by V -1- aside. ua
ran
ir s tee
tho
u or
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ss
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
– Now you can access the securing bolt on the retaining clamp
t to the co
-arrow- for the oil return line on the turbocharger support. Undo
screw -arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
g
– Remove connection pipe -2- leading to cooler for exhaust gas

n
t.
yi Co
recirculation. Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew upper bolt -arrow- from support on turbocharger.

– Catch leaking oil with used oil collection and extraction unit -
V.A.G 1782- .
4. Oil circuit 183

Caddy 2011 ➤
– Loosen banjo bolt -10- of oil supply line -2- on crankcase.

– Loosen banjo bolt -9- from support of turbocharger -8- on
crankcase.
– Unscrew bolts -1- from combination flange (oil supply and re‐
turn) on turbocharger.
– Remove combination flange (oil supply and return) together
with turbocharger support -8-.
Installing
AG. Volkswagen AG d
agen oes
Vol
ksw not
gu
y
db ara
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Note au ra
c
ss
ce
le
un
pt
♦ Renew gaskets, seals, O-rings and self-locking nuts ⇒ Elec‐
an
d
itte
tronic parts catalogue (ETKA)
y li
erm
ab
ility
♦ Replace particulate filter clip ⇒ Electronic parts catalogue
ot p
wit
(ETKA)
is n
h re
ole,
♦ If the particulate filter or the exhaust gas pressure sensor 1 -
spec
G450- has been renewed, it is absolutely necessary to adapt
t to the co
the exhaust gas pressure sensor 1 - G450- using ⇒ Vehicle
diagnostic tester.
♦ After working on the exhaust system, ensure that the system
rrectne
is not under stress and that there is sufficient clearance to the
bodywork. If necessary, loosen double clamp and align si‐
s
lencer and exhaust pipe so that sufficient clearance is main‐
s o
cial p
f
tained to the bodywork and the support rings are evenly
inform
loaded.
mer
atio
m
• The work procedure must be followed to ensure that the com‐

o
n
c
i
or
n
bined flange (oil supply and return line) together with the
thi
te
turbocharger support are installed tension-free.

sd
iva
o
pr
cum
r
• This ensures that the turbocharger support is installed tension-

fo
en
ng
free between crankcase and turbocharger.

t.
yi Co
Cop py
t. rig
gh ht
yri
– Place combined flange (oil supply and return line) on turbo‐ p by
o Vo
by c
charger and turbocharger support -8- on turbocharger and
lksw
cted agen
Prote
crankcase.
AG.
– Fit oil supply line -2- on crankcase.

– First, install turbocharger support -8- with banjo bolt -9- on
crankcase and turbocharger bolts -1- by hand.
– Then tighten turbocharger support -8- alternately with banjo
bolt -9- and bolts -1- in increments on crankcase and turbo‐
charger until torque setting is reached.
– Then tighten banjo bolt -10- of oil supply line -2- on crankcase.
– Finally, tighten clamp bolt -7- for oil supply line/turbocharger
support.
Install particulate filter ⇒ page 332 .
Installation position of exhaust gas temperature sender - G235- .

Caddy 2011 ➤
Angled shaft must have a distance -a- = 3 … 5 mm to bolting of

turbocharger support.
Torque settings
♦ ⇒ “4.1 Assembly overview - oil circuit”, page 180
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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un
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es, in part or in w
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tion in
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Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
4. Oil circuit 185

Caddy 2011 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Connection diagram - coolant hoses”, page 186 n AG. Volkswagen AG do
lkswage es n
⇒ “1.2 Draining and adding coolant”, page 187 by Vo ot g
ua
d ran
ir se
⇒ “1.3 Checking cooling system for leaks”,uthpage 192
o tee
or
a ac
ss
⇒ “1.4 Checking engine oil cooler for leaks”, page 193
ce
le
un
pt
1.1 Connection diagram - coolant hoses
an
d
itte
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rm
ab
pe
ility
ot
wit
1 - Expansion tank
, is n
h re
hole
2 - Radiator/cooler
spec
es, in part or in w
❑ For exhaust gas recircu‐
t to the co
lation
3 - Heat exchanger for heater
rrectness of i
❑ With quick-release cou‐
pling
l purpos
4 - Cylinder head/cylinder
block
nform
ercia
5 - Engine oil cooler

m
a
com
tion in
6 - Coolant circulation pump -
r
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V178-
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7 - Upper coolant hose

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pling t. Cop py
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8 - Radiator/cooler p by
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Prote AG.
⇒ page 209
9 - Lower coolant hose
pling
10 - Coolant pump/thermostat
⇒ page 198
11 - Supplementary heater
❑ If fitted
186 Rep. gr.19 - Cooling

Caddy 2011 ➤
1.2 Draining and adding coolant

equipment required
♦ Refractometer - T10007 A-
♦ Drip tray for workshop hoist AG. Volkswagen AG d
- VAS 6208- agen oes
olksw not
y V gu
d b ara
♦ Hose clamp pliers - VAS orise nte
6340- auth eo
ra
ss c
♦ Coolant system charge unit
ce
e
nl
pt
- VAS 6096-
du
an
itte
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♦ Adapter for cooling system
erm
ab
ility
tester - V.A.G 1274/8-
ot p
wit
, is n
♦ Engine bung set - VAS
h re
hole
6122-
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
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n in
or c
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te
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by
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Prote AG.
1. Cooling system/coolant 187

Caddy 2011 ➤
Draining
WARNING
Danger of scalding due to steam and hot coolant.

On a warm engine, the cooling system is under high pressure.
Reduce excess pressure by covering the cap of the coolant
expansion tank with cloths and opening it carefully. . Volkswage
AG n AG d
agen oes
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d b ara
– Open filler cap on coolant expansion
orise tank. nte
eo
th
u ra
– Remove noise insulation ⇒ sGeneral
sa body repairs, exterior; c
ce
e
nl
pt
du
an
– Place drip tray - VAS 6208- beneath engine.
itte
y li
erm
ab
ility
ot p
– Remove air intake hose. To do this, loosen hose clips -1- and
wit
, is n
-2-.
h re
hole
spec
es, in part or in w
Note
t to the co
To prevent ingress of coolant, seal connection on charge air cool‐
rrectness of i
er using a clean plug from engine bung set - VAS 6122- .
l purpos
nform
mercia
at
om
ion
c
– Pull coolant hose -arrow- off coolant circulation pump 2 -

in t
or
his
V178- .
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.
– Disconnect lower coolant hose from radiator. To do this, lift up

retaining clip -arrow- and drain coolant.

Caddy 2011 ➤
– In addition to draining coolant from engine, pull coolant hose

off engine oil cooler -arrow-.
Note
Please observe disposal instructions!
Filling
lkswage es n
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es, in part or in w
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nform
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tion in
r
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cum
fo
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t.
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Cop py
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Vo
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by
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189
Prote AG.
1. Cooling system/coolant
Caddy 2011 ➤
lkswage es n
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yV
Note d b ua
ran
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♦ Only distilled water may be used for mixing scoolant
s a additives. ac
The use of distilled water ensures optimum protection against
ce
e
nl
pt
corrosion.
du
an
itte
y li
♦ The water used for mixing has a major influence on the effec‐
erm
ab
ility
tiveness of the coolant. Since water quality differs from country
ot p
to country and even region to region, it is necessary to set a
wit
, is n
h re
standard for the quality of water to be used. Distilled water
fulfils all requirements. It is therefore recommended to use hole
spec
distilled water when mixing coolant for topping up or replacing
es, in part or in w
t to the co
coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic parts catalogue (ETKA) . Other coolant additives may
rrectness of i
reduce corrosion protection substantially. The resulting dam‐
l purpos
age could lead to loss of coolant and subsequent severe

damage to the motor.
nf
ercia
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
or
rosion damage as well as scaling. Such additives also raise
m
m
atio
the boiling point of the coolant. For this reason, the cooling
om
n in
system must be filled all-year-round with coolant additives.
or c
thi
te
♦ Because of its high boiling point, the coolant improves engine
sd
iva
o
r
reliability under heavy loads, particularly in countries with trop‐

rp
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ical climates.
f
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ng
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op
♦ The refractometer - T10007A- must be used to determine the
C py
t. rig
gh
current anti-freeze value.
ht
pyri by
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by
♦ Frost protection must be guaranteed down to -25°C as a min‐
cted agen
Prote AG.
imum and, in countries with arctic conditions, down to approx.
-36°C. Increasing the frost protection is permissible only if cli‐
matic conditions require stronger frost protection. It may, how‐
ever, be increased only to a maximum of -48 °C. Otherwise,
the cooling effect will be impaired.
♦ The coolant concentration must not be reduced by adding wa‐
ter even in warmer seasons and in warmer countries. Frost
protection must be guaranteed down to at least -25°C.
♦ Read off anti-freeze figures for respective replenished coolant
additives.
♦ The temperature read off the refractometer - T10007A- corre‐
sponds the »ice flocculation point«. Flakes of ice may start
forming in the coolant below this temperature.
♦ Never reuse old coolant.
♦ Use only a water/coolant additive mixture as a slip agent for
coolant hoses.
Recommended mixture ratios:

Frost Coolant additive Coolant ad‐ Distilled wa‐
protection to concentration ditive 1) ter 1)
-25°C 40% 3.2 l 4.8 l
-36°C 50% 4.0 l 4.0 l
1)The quantity of coolant can vary depending upon the vehicle
equipment.
– Reconnect coolant hoses, and secure them with clamps.

Caddy 2011 ➤
– 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 to 10 bar.
– Open valve -B-; turn lever in direction of flow to do this.

• In cooling system, vacuum is generated by suction jet pump;
needle of gauge must move into green area.
– In addition, open valve -A- briefly by turning lever in direction
of flow until expansion tank hose of cooling system charge unit
- VAS 6096- fills with coolant.
– Close valve -A- again. AG. Volkswagen AG d
agen oes
lksw not
– Leave valve -B- open for a further b2y Vminutes.
o gu
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is nte
• Vacuum continues to be generated
ut
hor
in the cooling system by eo
the suction jet pump; the needle
ss a of gauge must remain in green ra
c
range.
ce
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nl
pt
du
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– Close valve -B-.

itte
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• The needle on the gauge should stop in the green zone. The
ility
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vacuum level in the cooling system is then sufficient for sub‐

wit
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sequent filling.
h re
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spec
es, in part or in w
t to the co
Note
♦ If the needle does not reach the green zone, repeat the proc‐
rrectness of i
ess.
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♦ If vacuum drops, cooling system must be checked for leaks.

nf
– Pull off compressed air hose.

ercia
orm
m
– Open valve -A-.

atio
om
n in
c
• The vacuum in the cooling system causes coolant to be ex‐

or
thi
tracted from coolant expansion tank of cooling system charge

te
sd
iva
unit - VAS 6096- and the cooling system to be filled.

o
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f
– Then, remove cooling system charge unit - VAS 6096- from

en
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t.
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coolant expansion tank again.
Co
Cop py
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– Fill coolant up to max. mark.
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Prote AG.

Caddy 2011 ➤
wage rail) - Edition 09.2016
e
ks s no
Vol t gu
by ara
Without cooling system charge unit - VAS r6096-ise
d
: nte
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– Slowly fill coolant in up to upper marking
ss
a of hatched field on ra
c
expansion tank.
ce
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nl
pt
du
an
– Fit expansion tank cap.
itte
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ab
– Start engine and maintain engine speed at approx. 2000 rpm
ility
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for about 3 minutes.
wit
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– Then run engine at idling speed until radiator fan cuts in.
hole
spec
es, in part or in w
– Check coolant level and top up as needed. When engine is at
t to the co
normal operating temperature, the coolant level must be at the
upper mark; when engine is cold, in the middle of the shaded
field.
rrectness of i
1.3 Checking cooling system for leaks
l purpos
nf
ercia
or
♦ Cooling system tester - V.A.G 1274 B-
m
m
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om
n in
or c
thi
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f
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t.
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Cop py
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pyri by
Vo
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by
cted agen
Prote AG.
♦ Adapter for cooling system tester - V.A.G 1274/8-
♦ Adapter for cooling system tester - V.A.G 1274/9-

Caddy 2011 ➤
• Engine at operating temperature.
WARNING
Risk of scalding from steam or hot coolant.

♦ On a warm engine, the cooling system is under high pres‐
sure.
♦ Reduce excess pressure by covering the cap of the cool‐
ant expansion tank with cloths and opening it carefully.
– Open filler cap on expansion tank.
– Fit cooling system tester - V.A.G 1274 B- with adapter -

V.A.G 1274/8- to coolant expansion tank.
– Build up pressure of approx. 1.0 bar using hand pump of cool‐
ing system tester.
– If this pressure is not maintained, locate and rectify leaks.
AG. Volkswagen AG d
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olksw not
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or eo
h
aut ra
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ce
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nl
pt
du
Checking pressure relief valve in filler cap:

an
itte
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erm
ab
– Fit cooling system tester - V.A.G 1274 B- with adapter -

ility
ot p
V.A.G 1274/9- to filler cap -1-.

wit
, is n
h re
– Build up pressure using hand pump of cooling system tester.

hole
spec
• The pressure relief valve must open at a pressure of 1.4 to

es, in part or in w
t to the co
1.6 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.
rrectness of i
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nform
ercia
1.4 Checking engine oil cooler for leaks

m
at
om
ion
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or
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ate
do
priv
cum
for
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t.
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

Caddy 2011 ➤

equipment required
♦ Hose clamps to 25 mm -
3094-
♦ Cooling system tester -
V.A.G 1274-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
♦ Pliers for spring-type clips -
VAS 5024 A-
AG. Volkswagen AG d
agen oes
♦ Drip tray for workshop hoist olks
w not
yV gu
- VAS 6208- se
d b ara
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ce
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un
pt
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erm
ab
ility
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wit
is n
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spec
t to the co
rrectness o
cial p
f inform
mer
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om
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or
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Caddy 2011 ➤

Without illustration:
♦ Expansion tank
♦ Sealing cap
♦ Commercially available plug
♦ Commercially available hose
Condition:
• Engine cold
Test sequence
– Loosen hose clip on engine oil cooler with spring-type clip pli‐
ers - VAS 5024- .
– Remove engine oil cooler with housing ⇒ page 171 .
Note
♦ Collect escaping coolant with drip tray - V.A.G 1306- or drip

tray - VAS 6208- .
♦ Collect leaking engine oil with a cleaning cloth, if necessary.
Checking when removed

– Clamp casing with the old gasket onto a suitable, flat clean
surface with the help of a bar clamp -4-.
– Attach plug -2- to venting connection
agen
AG. Vof
olkexpansion
swagen AG tank -1-.
d w oes
olks no
– Attach coolant hose -3-
d b to engine oil cooler -5- and to expan‐
yV t gu
ara
sion tank -1-. orise nte
e h
ut or
– Fill expansionsstank
a
up to max. mark. ac
ce
e
nl
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
pt
du
an
system tester - V.A.G 1274/8- on coolant expansion tank -1-.

itte
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erm
ab
– Generate about 1.6 bar pressure using hand pump of tester.

ility
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– Observe pressure drop on pressure gauge. A pressure drop

h re
within 10 minutes is not permitted.

hole
spec
es, in part or in w
If the pressure drops:

t to the co
– Renew engine oil cooler ⇒ page 171 .

rrectness of i
– Renew housing seal.

l purpos
– Check coolant level and, if necessary, replenish ⇒ page 187 .

nform
ercia
– Check engine oil level and, if necessary, replenish

⇒ page 165 .
m
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om
ion
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ate
do
priv
cum
for
en
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t.
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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
195
AG.
1. Cooling system/coolant
Caddy 2011 ➤
2 Coolant pump, regulation of cooling

system
⇒ “2.1 Assembly overview - coolant pump, thermostat”,
page 196
⇒ “2.2 Assembly overview - coolant pump and thermostat, from
week 22/2011”, page 197
⇒ “2.3 Removing and installing coolant pump”, page 198
⇒ “2.4 Removing and installing 4/2-way valve with thermostat”,
page 199
⇒ “2.5 Removing and installing coolant temperature sender G62
”, page 204
⇒ “2.6 Removing and installing radiator outlet coolant tempera‐
ture sender G83 ”, page 205
AG. Volkswagen AG d
agen
2.1 Assembly overview - coolant pump, thermostat
oes
olksw not
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1 - Coolant pump ss a c
ce
le

un
pt
⇒ page 198
an
d
itte
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erm
ab
2 - Bolt
ility
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❑ 15 Nm.
wit
is n
h re
ole,
3 - O-ring
spec
t to the co
4 - O-ring
rrectne
5 - 4/2-way valve with thermo‐
stat
ss o
❑ The thermostat is loca‐

cial p
f i
ted within the 4/2-way

nform
valve and cannot be re‐

mer
atio
new individually.
om
n
c

i
or
n thi
⇒ page 199
te
sd
iva
o
pr
6 - Bolt
um
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fo
en
ng
❑ 15 Nm.
t.
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Cop py
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rig ht
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co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
2.2 Assembly overview - coolant pump and thermostat, from week 22/2011
1 - Bolt
❑ 15 Nm.
2 - 4/2-way valve upper part
4/2-way valve
⇒ page 199 .
3 - Thermostat
❑ Starts to open at 92°C
❑ Completely open at
107°C
AG. Volkswagen AG d
4 - O-ring agen oes
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❑ Renew after removal d by ara
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5 - 4/2-way valve lower partaut ra
c
ss
ce
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un
4/2-way valve
pt
an
d
itte
⇒ page 199 .
y li
erm
ab
6 - Bolt
ility
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wit
is n
❑ 4.5 Nm.
h re
ole,
7 - O-ring
spec
t to the co
8 - O-ring
rrectne
9 - Coolant pump
ss
o
cial p
⇒ page 198 f inform

mer
10 - Bolt
atio
m
❑ 15 Nm.
o
n
c
i
or
n thi
te
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o
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fo
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 197

Caddy 2011 ➤
2.3 Removing and installing coolant pump

equipment required
♦ Drip tray for workshop hoist
- VAS 6208-
♦ Torque wrench
(5 … 50 Nm) - V.A.G 1331-
♦ Pliers for spring-type clips -
VAS 6362-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Removing
nform
ercia

m
at
om
io
– Remove poly V-belt ⇒ page 48 .

n
c
in t
or
his
e

at
do
priv
– Remove coolant pump bolts -1- and carefully remove coolant

um
for
en
g
pump -2-.
n
t.
yi Co
op py
Installing
t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Note
♦ Renew gaskets and seals.

♦ The coolant pump plug faces downwards.

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

– Insert coolant pump -2- into cylinder block, and tighten bolts
-1-.
– Install toothed belt ⇒ page 121 .
. Volkswagen AG
– Install poly V-belt ⇒ page 48 . kswagen AG does
not
ol
yV gu
– Add coolant ⇒ page 187 ed.b ara
nte
ris
ho eo
Torque settings aut ra
c
ss
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
ce
le
un
pt
page 196
an
d
itte
y li
rm
ab
♦ ⇒ “2.2 Assembly overview - coolant pump and thermostat,
pe
ility
from week 22/2011”, page 197
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
2.4 Removing and installing 4/2-way valve with thermostat
rrectness of i
l purpos

equipment required
nform
ercia
♦ 10 mm jointed spanner -
3185-
m
a
com
tio
n in
r
te o
thi
♦ Hexagon bit, long reach -
s
iva
T10058- do
r
rp
cum
fo

en
ng
t.
yi Co
1331/- t. Cop py
rig
gh ht
♦ Drip tray for workshop hoist yri
p by
o Vo
- VAS 6208-
by c lksw
cted agen
Prote AG.
♦ Hose clamp pliers - VAS
6340-

Caddy 2011 ➤
Note
The thermostat is located within the 4/2-way valve and cannot be

renew individually.
Removing
pipe ⇒ page 306 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Remov‐

ing and installing alternator .
– Guide alternator with extreme caution past radiator to prevent
damaging it.
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
– Pull wiring harness clip -arrow- out of bracket.

es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Lay wiring harnesses -arrows- and connector -1- on bracket

to one side.

– Free electrical lines and hoses on left air pipe from fittings us‐
ing removal lever - 80 - 200- , and lay them to one side.
– Loosen hose clip -3- and remove left air pipe.
Note
-Items 1, 4- can be disregarded.
– Loosen hose clips -1- and pull coolant hoses off.
Note
AG. Volkswagen AG d
agen oes
-Items 2, 3, 4- can be disregarded. olksw not
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d b ara
rise nte
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au ra
ss c
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
wit
, is n
h re
– Remove electrical connector -1- for Hall sender - G40- from
hole
bracket.
spec
es, in part or in w
– Unscrew bolts -arrows- and pull front coolant pipe to one side
t to the co
away from 4/2-way valve.

rrectness of i
Note
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.

Caddy 2011 ➤
– Pull out coolant pipe from connection -C- of 4/2-way valve but
leave in installation position.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
Instructions for hose connections ⇒ page 235
hole
spec
es, in part or in w
– Open clamp -2-.
t to the co
– Disconnect electrical connection -1- on charge pressure send‐
er - G31- / intake air temperature sensor - G42- and remove
rrectness of i
right charge air pipe.
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
ht. rig
– Unscrew bolt -1-. rig ht
py by
co Vo
by lksw
– Press off clip -2- using removal lever - 80 - 200- . cted agen
Prote AG.
– Pull out oil dipstick guide tube from cylinder block upwards and
push to one side.

Caddy 2011 ➤
– Remove throttle valve module - J338- ⇒ page 302 .
– Pull coolant hoses off connections -A, B and D-.

– Unscrew bolts -3- for 4/2-way valve -2-.
– Pull out valve from cylinder block.
Installing
– Clean and smoothen sealing surface for O-ring.
– Moisten new O-ring -1- with coolant.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
– Thread 4/2-way valve in past ancillary bracket in direction of
ce
le
un
pt
oil filter module.

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
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fo
en
ng
t.
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Cop py
t. rig
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yri by
203
op Vo
by c lksw
Prote
cted AG.
agen 2. Coolant pump, regulation of cooling system
Caddy 2011 ➤
– Insert connection -2- of 4/2-way valve with O-ring -1- into cyl‐
inder block with slight rotary motions. n AG. Volkswagen AG do
wage e s no
olks t gu
yV
edb ara
ris nte
tho eo
au ra
c
ss
ce
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un
pt
an
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itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
t to the co
– Thread coolant pipe into connection -C- of 4/2-way valve.
– Tighten bolts -3- using T-bar and socket, 10 mm - 3185- .
rrectne
– Install charge air pipe ⇒ page 234 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
ss
and installing alternator .
o
cial p
f in
– Install throttle valve module - J338- ⇒ page 302 .
form
mer
atio
om
n
c
i
or
n
Torque settings
thi
te
sd
va
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,

i
o
pr
cum
page 196
r
fo
en
ng
t.
yi Co
♦ ⇒ “2.2 Assembly overview - coolant pump and thermostat, Cop py
from week 22/2011”, page 197 ht. rig
rig ht
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co Vo
by lksw
cted
2.5 Removing and installing coolant temper‐
agen
Prote AG.
ature sender - G62-

Removing
• Engine cold.

Caddy 2011 ➤
– Briefly open filler cap for coolant expansion tank in order to

reduce pressure in cooling system.

– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
Note
AG. Volkswagen AG d
agen oes
lksw not
Disregard -items 1, 2, 4, 5-. d by
Vo gu
ara
ise nte
or eo
h
aut ra
ss c
– Pull connector -4- off coolant temperature sender - G62- .
ce
le
un
pt
an
d
itte
y li
erm
ab
Note
ility
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wit
is n
Place a cloth under connecting piece to absorb escaping coolant.
h re
ole,
spec
– Pull off retaining clip -3- and pull coolant temperature sender
t to the co
- G62- out of screw connection.
rrectne
Note
s
s o
cial p
f inform
Installing
mer
atio
m

o
n
c
i
or
n thi
te
sd
va
Note
i
o
pr
cum
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fo
en
ng
t.
♦ Renew O-ring.
yi Co
Cop py
t. rig
♦ Insert new coolant temperature sender - G62- immediately in‐ gh ht
yri by
to union to avoid loss of coolant.
op Vo
by c lksw
cted agen
Prote AG.
– Check coolant level and top up if necessary ⇒ page 187 .
2.6 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.

Caddy 2011 ➤
– Briefly open filler cap for coolant expansion tank in order to

reduce pressure in cooling system.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
ho eo
– Loosen bolta -1-.
ut ra
c
ss
ce
le
un
pt
an
d
itte
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
y li
rm
ab
with fuel hoses -5- and -6- connected.
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
– Pull connector -2- off radiator outlet coolant temperature send‐

do
r
rp
er - G83- .
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fo
en
ng
t.
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Cop py
t. rig
Note opyri
gh by
Vo
ht
c by lksw
cted
Place a cloth underneath to absorb escaping coolant.
agen
Prote AG.
– Pull off retaining clip -1- and pull coolant temperature sender
at radiator outlet - G83- out of screw connection of coolant
pipe.
Installing
Note
♦ Renew O-ring.
♦ Insert new coolant temperature sender - G83- immediately in‐
to coolant pipe at radiator outlet to avoid loss of coolant.
– Check coolant level and top up if necessary ⇒ page 187 .

Caddy 2011 ➤
3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator/radiator fan”, page 207
⇒ “3.2 Removing and installing cowling together n with radiator
AG. Volkswagenfan
AG do
V7 and radiator fan on right of radiator VV35 wage
olks ”, page 208
es n
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y ua
db ran
⇒ “3.3 Removing and installing radiator”,
or
ise page 209 tee
th or
au
3.1 Assembly overview - radiator/radiator fan s ac
s
ce
e
nl
pt
du
an
itte
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1 - Radiator/cooler
erm
ab
ility
ot p
❑ After renewing, renew
wit
entire coolant.
, is n
h re
hole
spec
⇒ page 209
es, in part or in w
t to the co
2 - O-ring
rrectness of i
3 - Upper coolant hose
l purpos

coolant hoses
⇒ page 186
nform
ercia
4 - Sealing cap
m
at
om
io
❑ Check using cooling
n
c
in t
r
system tester -
o
his
e
V.A.G 1274- and adapt‐

at
do
riv
er - V.A.G 1274/9-
p
cum
or
⇒ page 192
f
en
ng
t.
yi Co
op
5 - Connector C py
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yri
6 - Bolt
p by
co Vo
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cted agen
5 Nm.
Prote AG.
7 - Expansion tank
❑ With coolant tempera‐
ture display sender -
G32- .
❑ Check cooling system
for leaks with cooling
system tester -
V.A.G 1274- and adapt‐
er - V.A.G 1274/8-
⇒ page 192
8 - Lower coolant hose
coolant hoses ⇒ page 186
9 - Nut
❑ 5 Nm.
10 - Bolt
❑ 5 Nm.
11 - Additional fan for radiator
12 - Main fan for radiator
13 - Connector
14 - Radiator cowl
3. Radiator, radiator fan 207

Caddy 2011 ➤
Connecting coolant hose with plug-in connector

– Remove old O-ring -2- in coolant hose -3-.
– Moisten new O-ring with coolant and insert into coolant hose.
– Push coolant hose into connection -1- until it audibly engages.
– Press again on coolant hose and check plug-in connector is
engaged correctly by pulling hose back. n AG. Volkswagen AG do
lkswage es n
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ss
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nl
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du
an
itte
3.2 Removing and installing cowling togeth‐
y li
erm
ab
er with radiator fan - V7- and radiator fan
ility
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wit
, is n
on right of radiator - V35-
h re
hole
spec
Removing
es, in part or in w
t to the co
– Remove air filter housing with connecting pipe ⇒ page 306 .
– If present, remove noise insulation ⇒ General body repairs,
rrectness of i
exterior; Rep. gr. 66 ; Body, front; Noise insulation .
l purpos
– Remove upper bolts -arrows- of air cowling.
nform
mercia
at
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ion
c
in t
or
his
ate
do
priv
cum
for
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ng
t.
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Cop py
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Vo
co lksw
by
cted agen
Prote AG.
– Pull back securing lever -1- onto stop
– Push down securing lever -2- and pull off connector

Caddy 2011 ➤
– Unscrew lower bolts -arrows-.

– Turn air cowling together with radiator fans anti-clockwise a
little and remove downwards.
Vehicles with 2 radiator fans
– Disconnect electrical connector -1- and free electrical wiring.

– Unscrew bolts -arrows- and remove radiator fans.
Vehicles with one radiator fan
– Unscrew bolts -arrows- and remove radiator fan.

Installing
Torque settings
. Volkswagen AG
gen AG d
♦ ⇒ “3.1 Assembly overview - radiator/radiator
Vol
ksw
a
fan”, page 207
oes
not
by gu
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oris eo
th
au ra
c
ss
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un
pt
an
d
itte
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erm
ab
ility
3.3 Removing and installing radiator

ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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or
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te
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fo
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t.
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Cop py
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Prote AG.
3. Radiator, radiator fan 209

Caddy 2011 ➤

equipment required
1783-
♦ Drip tray for workshop hoist AG. Volkswagen AG d
- VAS 6208- agen oes
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nl
pt
du
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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.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Noise insulation .
– Remove air filter housing with connecting pipe ⇒ page 306 .
– Removing and installing air cowling together with radiator fan
- V7- and right radiator fan - V35- ⇒ page 208 .
– Pull coolant hoses off radiator.
– Remove radiator securing bolts ⇒ Item 10 (page 207) and re‐
move radiator.
Installing
Torque settings
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 207

Caddy 2011 ➤
4 Coolant pipes
⇒ “4.1 Assembly overview - coolant pipes”, page 211
⇒ “4.2 Removing and installing lower coolant pipe”, page 212
⇒ “4.3 Removing and installing upper coolant pipe”, page 216
⇒ “4.4 Removing and installing left coolant pipe”, page 217
⇒ “4.5 Removing and installing right coolant pipe”, page 219
4.1 Assembly overview - coolant pipes
1 - Grommet
❑ Not sold separately. AG. Volkswagen AG d
agen oes
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2 - Sleeve d b ara
rise nte
❑ Not sold separately. autho eo
ra
ss c
3 - Bolt
ce
le
un
pt
❑ 3 Nm.
an
d
itte
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erm
ab
4 - Bolt
ility
ot p
❑ 40 Nm.
wit
is n
h re
ole,
5 - Holder
spec
❑ For coolant circulation
t to the co
pump 2 - V178-
6 - Coolant pipe
rrectne
❑ Front
7 - O-ring
ss
o
cial p
f inform
8 - Coolant pipe
mer
atio
❑ right
om
n
c
9 - O-ring
or
n thi
te
sd
a

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pr
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fo
10 - Radiator outlet coolant

en
ng
t.
temperature sender - G83-
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Cop py
t. rig
11 - Retaining clip
gh ht
pyri by
Vo
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by
12 - Bolt Prote
cted AG.
agen
❑ 8 Nm.
13 - Nut
❑ 8 Nm.
14 - Bolt
❑ 8 Nm.
15 - Coolant line
16 - Bolt
❑ 8 Nm.
17 - Gasket
18 - Union
19 - Bolt
❑ 8 Nm.
4. Coolant pipes 211

Caddy 2011 ➤
20 - Retaining clip
21 - Radiator outlet coolant - G62-
22 - O-ring
23 - Double stud
❑ 8 Nm.
24 - Bolt
❑ 8 Nm.
25 - Coolant pipe
❑ left
26 - Bolt
❑ 8 Nm.
27 - Bolt
❑ 40 Nm. n AG. Volkswagen AG do
swage es n
28 - Bolt byV
olk ot g
ua
d ran
❑ 13 Nm. ir se tee
tho
u or
a ac
29 - Coolant circulation pump 2 - V178- ss
ce
e
nl
pt
du
an
itte
y li
erm
4.2 Removing and installing lower coolant
ab
ility
ot p
pipe
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.

Caddy 2011 ➤
Removing
– Remove air filter housing
agen
AG.⇒
Vopage
lkswag306
en AG.
do w es n
olks o
– Disconnectd bearth
y V wire -arrow- from battery with ignition
t gu
ara switch‐
ed off ⇒orisElectrical
e
system; Rep. gr. 27 ; Disconnecting
nte
e and
h
reconnecting
au
t battery . or
ac
ss
– Remove battery ⇒ Electrical system; Rep. gr. 27 .
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
– Remove battery carrier. Unscrew bolts -arrows-.

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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te
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Cop py
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Prote AG.

Caddy 2011 ➤
– Remove crankcase breather hose -1- from cylinder head cov‐

er. To do this, press release buttons.
– Expose vacuum hoses -arrows- at air pipe.
– Swing air pipe together with intake connection towards rear
and pull them off the turbocharger.
– Unclip wiring harness from bracket -arrow-.

Vehicles with dual clutch gearbox:
. Volkswagen AG
gen AG does
swa
– Clamp off coolant hoses using hose clamps
by
Vol to 25 mm - 3094-
k not
gu
and remove from gear oil cooler. To
ris
edo this, loosen hose clips
d ara
nte
-arrows-. ut
ho eo
ra
a c
ss
ce
e
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
– Lay wiring harnesses -arrows- and electrical connector -1- on

rrectness of i
bracket to side.
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nf
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by
cted agen
Prote AG.

Caddy 2011 ➤
-2-.

lever - 80 - 200- .
Note
– Loosen hose clips -1- and pull off coolant hoses.
Note
-Items 2, 3, 4- can be disregarded.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
– Remove electrical connector -1- for Hall sender - G40- from

ility
ot p
bracket.
wit
is n
h re
– Remove bracket from front coolant pipe.

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

Caddy 2011 ➤
– Loosen hose clamps -2- -3- and pull off coolant hoses.
– Unscrew bolts -arrows- and pull front coolant pipe out of 4/2-
way valve.
Installing
olkswagen AG
en AG. V
olks
wag does
not
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Note au ra
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ss
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un
♦ Renew gaskets, seals and O-rings.
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Clean or smoothen sealing surface for O-ring.
– Moisten O-ring with coolant and slide onto front coolant pipe.
rrectne
– Push front coolant pipe into 4/2-way valve.
ss
o
cial p
f
inform
bocharger. -arrow-.
mer
atio
m

o
n
c
i
or
n
Torque settings
thi
te
sd
iva
o
♦ ⇒ “4.1 Assembly overview - coolant pipes”, page 211
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.
4.3 Removing and installing upper coolant

pipe
♦ Hose clamp pliers - VAS 6340-

Caddy 2011 ➤
Removing
– Loosen hose clips -1- and -3- and pull off coolant pipe.
– Remove top coolant pipe at front.
Installing
– Add coolant ⇒ page 187 . AG. Volkswagen AG d
agen oes
ksw not
Torque settings byV
ol
gu
ara
ed
is nte
♦ ⇒ “4.1 Assembly overview
hor
- coolant pipes”, page 211 eo
aut ra
s c
♦ ⇒ “6.1 Assembly soverview - air filter housing”, page 305
ce
e
nl
pt
du
an
itte
4.4 Removing and installing left coolant pipe

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

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut 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
ercia

m
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.
Removing
– Lay wiring harnesses -arrows- and electrical connector -1- on
bracket to side.

Caddy 2011 ➤
-2-.

lever - 80 - 200- .
– Clamp off coolant hoses with hose clamps to 25 mm - 3094-
and loosen hose clips -1- and -4-.
– Pull coolant hoses off left coolant pipe.
– Remove rear left coolant pipe.
Installing agen
AG. Volkswagen AG d
oes
olksw not
V
Install in reverse order d b of removal. During this step, observe
y gu
ara the
following: rise nte
tho eo
au ra
ss c
ce
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nl
Note
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

Torque settings
rrectness of i

l purpos

nf
ercia
4.5 Removing and installing right coolant

rm
m
atio
m
pipe
o
n in
or c
thi
e

t
sd
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o
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f
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ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
olks
wage es n
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yV ua
db ran
ir se tee
ho
aut or
ac
ss
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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.
yi Co
Cop py
t. rig
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pyri by
Removing
co Vo
by lksw
cted agen
Prote AG.
– Loosen bolt -1-. Unscrew bolt -2- and nut -3-.
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
pairs, exterior; Rep. gr. 66 ; Wheel housing liners; Front wheel
housing liners .

Caddy 2011 ➤
– Pull connector -3- off radiator outlet coolant temperature send‐

er - G83- .
– Clamp off coolant hoses using hose clamps, up to 25 mm -
3094- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
– Loosen hose clips -arrows- and pull coolant hoses off right
un
pt
coolant pipe.
an
d
itte
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erm
ab
– Unscrew nut -1- and bolt -2- and remove right coolant pipe.
ility
ot p
wit
Installing
is n
h re
ole,
spec
t to the co
Torque settings
rrectne
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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o
pr
cum
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fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
21 – Turbocharging/supercharging
1 Exhaust turbocharger
⇒ “1.1 Assembly overview - turbocharger”, page 222
⇒ “1.2 Removing and installing turbocharger ”, page 226
⇒ “1.3 Removing and installing charge pressure control solenoid
valve N75 ”, page 231
1.1 Assembly overview - turbocharger

⇒ page 9
Note
♦ Sealed bolts and nuts must not be loosened.

♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
♦ Before installing the turbocharger, fill the oil supply channel
(smaller diameter) with a »splash« of engine oil “to prevent a
dry start up”.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
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
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nf
ercia
orm
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atio
om
n in
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te
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f
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ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
222 Rep. gr.21 - Turbocharging/supercharging

Caddy 2011 ➤
1 - Exhaust gas recirculation

pipe
❑ With flexible joint; do not
bend flexible joint - risk
of cracking
wage
2 - Gasket olks es n
ot g
byV ua
❑ Renew after removalrised ran
tee
tho
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3 - Bolt ss
a ac
ce
e
nl
pt
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an
❑ 17 Nm.
itte
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erm
ab
4 - Union
ility
ot p
wit
❑ With oil supply line and
, is n
h re
oil return line.
hole
spec
❑ Before installing, ensure
es, in part or in w
that oil supply line is not
t to the co
blocked.
rrectness of i
⇒ page 180 .
l purpos
5 - Gasket
nf
ercia
6 - Nut
orm
m
atio
❑ 24 Nm.
om
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c
7 - Heat shield
or
thi
te
sd
iva
8 - Exhaust turbocharger
o
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rp
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❑ Must only be renewed
f
en
ng
t.
together with exhaust
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op
manifold and position
C py
t. rig
gh
sender for charge pres‐
ht
pyri by
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o
sure positioner - G581- .
c by lksw
cted agen
Prote AG.
❑ Installation position of
connecting hose at tur‐
bocharger ⇒ page 225
❑ Note tightening sequence and installation procedure ⇒ page 225 .
9 - Retaining ring
❑ Installation possible in one position only.
❑ Installation position in pulsation damper ⇒ page 225 .
10 - O-ring
11 - Pulsation damper
❑ Installation position of intake hose at pulsation damper ⇒ page 225
12 - Bolt
❑ 9 Nm.
13 - Intake connecting pipe
14 - Bolt
❑ Attached in inlet connection.
❑ 9 Nm.
15 - O-ring
1. Exhaust turbocharger 223

Caddy 2011 ➤
16 - Holder
❑ For electrical cables
17 - Bolt
❑ 8 Nm.
18 - Heat shield
19 - Gasket
20 - Nut
❑ Note tightening sequence and installation procedure ⇒ page 225 .
❑ 25 Nm.
21 - Exhaust gas temperature sender 1 - G235-
❑ Installation position ⇒ page 225
22 - Bolt
❑ 20 Nm.
23 - Support
AG. Volkswagen AG d
❑ For turbocharger agen oes
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❑ Before installing oil supply line, ensure edthat
b it is not blocked ara
nte
ris
❑ Before installing, fill turbochargerawith
ut
ho
engine oil through oil supply line connection eo
ra
s c
❑ Removing and installing ⇒ pages 180 .
ce
le
un
pt
24 - Bolt
an
d
itte
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❑ 9 Nm.
erm
ab
ility
ot p
25 - O-ring
wit
is n
h re
❑ Various diameters.
ole,
spec
26 - Banjo bolt t to the co

❑ Renew complete with O-rings
rrectne
❑ 60 Nm.
27 - Oil seals
ss o

cial p
f inform
28 - Banjo bolt
mer
atio
❑ Renew complete with O-rings

om
n
c
❑ 30 Nm.
i
or
n thi
te
sd
a
29 - O-ring
iv
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pr
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r

fo
en
ng
t.
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30 - Nut t. Cop py
rig
gh
❑ 24 Nm.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Tightening sequence and procedure

♦ Position turbocharger on studs on cylinder head.
♦ Tighten nuts -1- to -8- in specified sequence. Then, tighten
nuts again in specified sequence.
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
e
Installation position of intake
horis
hose at turbocharger nte
eo
aut ra
– Fit connecting hosess in such a way that the “extension” -2- of c
ce
e
the connecting hose is in contact with the corner of the name‐

nl
pt
du
plate -2-.
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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
rrectness of i
Installation position of connecting hose
l purpos
– Install connecting hose in such a way that marking -1- on con‐

necting hose is opposite marking -2- on pulsation damper.
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
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Cop py
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Installation position of exhaust gas temperature sender with an‐ Prote AG.
gled cable guide
Note
When installing the exhaust temperature sender with angled ca‐

ble guide, adhere to dimension -a- of 3 … 5 mm from the turbo‐
charger support threaded connection.
Installation position of O-ring and seals in pulsation damper

Caddy 2011 ➤
1 - Damper
❑ With grooves.
2 - O-ring
3 - Sealing ring
❑ With spring
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1.2 Removing and installing turbocharger h re

hole
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es, in part or in w
t to the co
♦ Lambda probe open ring spanner set - 3337-

rrectness of i
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tion in
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op
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- C py
t. rig
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Prote AG.

Caddy 2011 ➤
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♦ Tool insert, AF 17 mm - T10395-
t to the co
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If a mechanical fault is discovered on the turbocharger (e.g. a
c by lksw
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destroyed compressor impeller), it is not sufficient to just renew Prote AG.
the turbocharger. To avoid any subsequent damage, the fol‐
lowing work must be carried out:
♦ Check air filter housing, air filter element and air inlet ho‐
ses for contamination.
♦ Check the whole charge air path and charge air cooler for
foreign objects.
♦ If foreign objects are discovered in the charge air system,
clean the charge air path and, if necessary, renew the
charge air cooler.
Removing
Note safety precautions ⇒ page 1 .
Observe rules for cleanliness ⇒ page 9 .
– Remove particulate filter ⇒ page 332 .
– Remove oil supply line and turbocharger support
⇒ page 180 .

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agen
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lksw l engine, common rail)es-nEdition
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y gu
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– Remove air filter housing
ut
ho with
r
air mass meter and connecting eo
pipe ⇒ page 306 . ss a ra
c
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nl
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ility
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spec
es, in part or in w
t to the co
rrectness of i
– Press release buttons and remove hose -1- for venting crank‐
l purpos
case.
– Unclip vacuum lines -arrows- and place to one side.
nf
ercia
orm
– Unscrew bolt -2- (captive bolt). Twist intake hose -3- clockwise
m
atio
m
out of its holder and remove it.

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– Open heat shield gaiter -1- from charge pressure servo posi‐
tion sender - G581- -3-.
– Disconnect and pull off electrical connector -2- on charge
pressure servo position sender - G581- -3-.
– Open bracket -2- and unhook vacuum hose -1-.

– Pull off vacuum hose -1- from vacuum unit on turbocharger.

Caddy 2011 ➤
– Disconnect electrical connector -2- for exhaust temperature

sender 1 - G235- and free electrical line.
– Carefully take the line out of the brackets on plenum chamber
bulkhead and on turbocharger.
– Unscrew bolt -1- from charge air pipe and undo the two clips
of the connecting hose.
– Remove pulsation damper.
AG. Volkswagen AG d
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– Take off pulsation damper -2-.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
i
– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
on
c
in t
lation.
or
his
ate
do
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for
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Prote AG.

Caddy 2011 ➤
– Unscrew bolts -1, 3-, union nut -2- and banjo bolts -4, 5-, and
remove turbocharger support with oil supply line.
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ir se tee
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– Unscrew boltss a-arrows-
u and remove heat shield. ac
s
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spec
t to the co
rrectness o
cial p
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mer
atio
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Prote AG.

Caddy 2011 ➤
– Unscrew nuts -arrows-.

– Remove turbocharger together with exhaust manifold from
cylinder head and turn so that the intake side is facing down‐
wards. Remove turbocharger together with exhaust manifold
downwards. gen AG
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Installing Vol gu
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Install in reverse thoorder, noting the following: eo
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Note
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♦ Renew seals, gaskets, O-rings and self-locking nuts.
ility
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♦ Fill turbocharger with engine oil at connection for oil supply
h re
line.
ole,
spec
t to the co
rrectne
♦ After installing turbocharger, run engine for about 1 minute at
s
idling speed to ensure that oil is supplied to turbocharger. Do
s o
cial p
not rev engine immediately.
f inform
mer
♦ Fit heat shield sleeves in the same place when installing.
atio
om
n
c
i
or
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Caution
t
sd
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fo
Before installing, check whether flexible joint of oil return line

en
ng
t.
is bent and thus stretched. If this is the case, micro-fractures op
yi Co
may have been caused and this will cause leaks. If necessary,
C py
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renew oil return line before installing turbocharger.
ht
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bocharger. -arrow-.
– Install exhaust gas recirculation pipes ⇒ page 348 .
– Installing exhaust temperature sender 1 - G235-
⇒ page 342 .
– Connect vacuum hoses ⇒ page 259 .
– Install particulate filter ⇒ page 332 .
Torque settings
♦ ⇒ “1.1 Assembly overview - turbocharger”, page 222
1.3 Removing and installing charge pres‐

sure control solenoid valve - N75-

Caddy 2011 ➤
AG. Volkswagen AG d
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ility
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spec
♦ Hose clamp pliers - VAS 6340-
es, in part or in w
t to the co
rrectness of i
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Removing
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– Unclip vacuum hoses -arrows- and place to one side. by c lksw
cted agen
Prote AG.
– Remove intake hose -3- on air filter.

Caddy 2011 ➤
– Pull off vacuum hoses -4-, -5- and -6- from charge pressure
control solenoid valve - N75- -2-.
– Release connectors -7- and pull off.
– Unscrew nuts -3- and remove charge pressure control sole‐
noid valve - N75- -2-.
Installing
Caution
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Vo ot g
Do not kink, twist or crush the vacuum lines when routing
ed
by vac‐ ua
ran
uum lines. This may cause breakdowns. thoris tee
or
au ac
Push all hoses onto stop or at least 10 mm onto
ss the respective
connection.
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– Install suction hose on turbocharger ⇒ page 222 .
ility
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– Tighten nuts -3-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
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tion in
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bocharger. -arrow-.
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Prote AG.

Caddy 2011 ➤
2 Charge air system

⇒ “2.1 Assembly overview - charge air system”, page 234
⇒ “2.2 Assembly overview - charge-air hose connections”,
page 235
⇒ “2.3 Removing and installing charge air cooler”, page 236
⇒ “2.4 Removing and installing charge air pipe”, page 238
⇒ “2.5 Removing and installing charge air pressure sender G31 /
intake air temperature sender G42 ”, page 239
⇒ “2.6 Checking charge air system for leaks”, page 239
2.1 Assembly overview - charge air system
1 - Intercooler
⇒ page 236
2 - Gasket
3 - Bolt
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5 - Bearings s aut ra
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6 - Screw-type clamp
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❑ Instructions for hose

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⇒ page 235
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7 - Air intake hose

h re
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spec
8 - Bolt
t to the co
❑ 5 Nm.
9 - Charge air pressure sender
- G31- / intake air temperature
rrectne
sender - G42-
ss
⇒ page 239
o
cial p
f inform
10 - O-ring
mer

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11 - Air intake pipe

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12 - Screw-type clamp
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❑ Instructions for hose

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connections
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⇒ page 235
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14 - Bolt
AG.
❑ 9 Nm.
15 - Grommet

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Caddy 2011 ➤
a
ss 4-cylinder diesel enginec (1.6 l engine, common rail) - Edition 09.2016
ce
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nl
pt
du
16 - Air intake hose
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itte
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17 - Air intake pipe
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18 - Sleeve
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19 - Bolt
spec
es, in part or in w
❑ 9 Nm.
t to the co
20 - Grommet
rrectness of i
21 - Air intake hose
l purpos
22 - Gasket
nform
mercia
at
Installing air hoses with screw-type clips
om
ion
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ate
Note
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In order to be able to securely attach the air hoses on their con‐

n
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nections, the worm screws of the used hose clips have to be
C py
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sprayed with penetrating spray before installing.
rig ht
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Specified torques for
AG.
1- Hose clip -a- = 13 mm wide: 5.5 Nm

2- Hose clip -b- = 9 mm wide: 3 Nm
2.2 Assembly overview - charge-air hose

connections
Caution
It is essential that the screw-type clamps on the charge air lines

are tightened to 5.5 Nm. If the tightening torque is too low or
too high, the charge air hose may slip off the charge air pipe
when the vehicle is being driven.
Conventional screw-type clips are used on the hose connections

on the “intake side”.
Screw-type clips with “barbs” -arrows- are used on the hose con‐
nections on the “discharge side”.
Caution
• Do not loosen these hose clips and pull them back over
the hose. Risk of damage to hose!
• If a clamp has been removed, it must be renewed together
with the hose.
2. Charge air system 235

Caddy 2011 ➤
Screw-type clips with locking hooks -arrows- may only be re‐

leased.
– Loosen bolt of screw-type clips -1- sufficiently to allow for re‐
moving hoses.
Screw-type clamps that have only been loosened can be re-used.
Hose and clamp are supplied together as one spare part.
– When installing, does not use any fluid containing oil, silicone
or grease. Only use clean water.
Note
♦ Check all air hoses and pipes for firm seating and leaks before
carrying out tests or repairs.
♦ Secure all hose connections with the same type of hose clips
as original equipment ⇒ Electronic parts catalogue .
♦ In order to be able to securely attach the air hoses on their
connections, the worm screws of the used hose clips have to
be sprayed with penetrating spray before installing.
Caution
The screw-type clips -A- on the charge air lines must always
be tightened as specified ⇒ page 235 . If the torque is too low
or too high, the charge air hose may slip off the corrugated pipe
connection or the charge air pipe when the vehicle is used.
AG. Volkswagen AG d
agen oes
olksw not
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2.3 Removing and installing charge air cool‐
s
ce
e
nl
pt
du
er
an
itte
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erm
ab
Removing
ility
ot p
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h re
-arrows-.
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
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orm
m
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Cop py
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rig ht
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co Vo
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236
cted agen
Prote AG.
Rep. gr.21 - Turbocharging/supercharging
AG. Volkswagen AG d
agen oes
olksw not
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aut
h
ra Caddy 2011 ➤
s c
s 4-cylinder diesel engine (1.6 l engine, common rail) - Edition 09.2016
ce
le
un
pt
an
d
itte
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ab
pe
ility
ot
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, is n
h re
hole
spec
es, in part or in w
t to the co
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nform
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a
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tion in
– Set lock carrier to service position ⇒ General body repairs,
r
te o
thi
exterior; Rep. gr. 50 ; Body - front; Lock carrier .
s
iva
do
r
rp
c
– Remove air filter ⇒ page 306 .
um
fo
en
ng
t.
yi
– Remove radiator together with connected coolant lines
Co
op py
⇒ page 209 . Then, secure radiator with wire.
. C rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.
– Unscrew bolts -arrows- from charge air cooler.

– Swing charge air cooler backwards slightly.
– Unscrew bolt from lower right refrigerant line bracket on

charge air cooler.
– Remove charge air cooler upwards.
Installing
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body - front; Lock carrier .
– Installing radiator ⇒ page 209 .
Torque settings
♦ ⇒ “2.1 Assembly overview - charge air system”, page 234
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 207

Caddy 2011 ➤ agen
AG. Volkswagen AG d
oes
ksw
4-cylinder diesel engine (1.6 l engine, common rail)
by
V - Edition 09.2016
ol not
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2.4 Removing and installing charge air pipe th or
au ac
ss
ce
le
un
pt
an
d
itte
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– Disconnect earth strap at battery with ignition switched off ⇒
rm
ab
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
pe
ility
battery.
ot
wit
, is n
h re
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
hole
spec
27 ; Battery; Removing and installing battery .
es, in part or in w
t to the co
pipe ⇒ page 222 .
rrectness of i
– Loosen clips -1- and -2- on connecting hose to pulsation
l purpos
damper. Unscrew securing bolt -3- from charge air pipe.

– Unscrew charge air pipe bolt -arrow-. Pull connecting hose off
nform
ercia
pulsation damper as far as possible.

m
a
com
tion in
r
te o
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Cop py
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pyri by
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Prote AG.
– Unclip top coolant hose on charge air pipe -arrow-.
– Unclip wiring harnesses from charge air pipe -arrows-.

AG. Volkswagen AG d Caddy 2011 ➤
agen oes
Volksw 4-cylinder diesel engine
not
gu
(1.6 l engine, common rail) - Edition 09.2016
by ara
ed
is ntee
– or
Removeuthconnecting hose -arrow-. or
a ac
ss
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erm
ab
ility
ot p
wit
is n
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ole,
spec
t to the co
rrectne
– Remove bolts -arrows- of charge air pipe.
ss
– Take out charge air pipe.
o
cial p
f inform
Installing
mer
atio
om
n
c
i
or
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– Renew any damaged cable ties and clips.
thi
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Torque settings
i
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en
ng

t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
2.5 Removing and installing charge air pres‐
sure sender - G31- / intake air tempera‐
ture sender - G42-
Removing
– Pull connector -2- off charge air pressure sender - G31- / in‐
take air temperature sender - G42- .
– Unscrew bolts -1- and pull charge pressure sender - G31- /
intake air temperature sender - G42- out of air pipe.
Installing
Torque settings
2.6 Checking charge air system for leaks


Caddy 2011 ➤
♦ Charge air system tester - V.A.G 1687-
♦ Adapter - V.A.G 1687/10-

AG. Volkswagen AG d
agen oes
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Removing aut
h
ra
ss c
– Remove crankcase breather hose -arrow- from air pipe. To do
ce
e
nl
pt
du
this, press release buttons.

an
itte
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erm
– Seal union with a bung -2- (diameter 28 mm) from engine bung
ab
ility
set - VAS 6122- and secure with a clip -1-.

ot p
wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
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thi
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t.
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Cop py
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Prote AG.

Caddy 2011 ➤
4-cylinder diesel engine
wagen (1.6
AG. Volkl sengine,
wagen AGcommon rail) - Edition 09.2016
doe
ks s no
Vol t gu
by ara
– Remove intake hose -1- from air filter.ris
ed
nte
tho eo
– Insert adapter - V.A.G 1687/10-ssinto
au intake hose -1- and se‐ ra
c
cure with a clip.
ce
e
nl
pt
du
an
Prepare charge air system tester - V.A.G 1687- as follows:
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
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
– Unscrew pressure control valve -2- completely and close
thi
te
sd
valves -3- and -4-.
iva
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o
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t.
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Note
Co
Cop py
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To turn the pressure regulating valve -2- the knob must be pulled
op Vo
by c lksw
upwards. cted agen
Prote AG.
– Connect charge air system tester - V.A.G 1687- to adapter -

V.A.G 1687/10- as shown.

Caddy 2011 ➤
– Connect compressed air hose -1- (compressed air supply) to

charge air system tester - V.A.G 1687- , using a standard con‐
necting piece.
Note
Drain water in sight glass by removing drain plug -6-.
– Open valve -3-.

AG. Volkswagen AG d
agen oes
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Caution ed by gu
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ut
The pressure must not exceed 0.5 bar. If the pressure is too
a ra
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high, this can cause damage to the charge air system.
ce
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nl
pt
du
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erm
ab
– Adjust pressure to 0.5 bar with pressure regulating valve -2-.
ility
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– Open valve -4- and wait until test circuit is full. If necessary,
, is n
h re
re-adjust pressure to 0.5 bar.
hole
spec
– Check charge air system for leaks as follows:
es, in part or in w
t to the co
♦ by listening
♦ by feeling
rrectness of i
♦ with leak detector spray
l purpos
♦ or with the ultrasonic tester - V.A.G 1842- .

nform
mercia
Note
at
om
ion
c
in t
r
♦ Slight leaks on the intake side of turbocharger are permissible,

o
his
te
as the intake hoses are not designed for high-pressure.

a
do
priv
cum
or
♦ A small amount of air escapes through the valves and enters

f
en
ng
the engine. Therefore a holding pressure test is not possible.

t.
yi Co
Cop py
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♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
ht ht
rig by
copy Vo
♦ Depressurise test circuit by detaching coupling from adapter -
by lksw
cted agen
Prote
V.A.G 1687/10- before removing adapter.
AG.

Caddy 2011 ➤
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 243
⇒ “1.2 Overview of fitting locations - injection system”,
page 245 wage
es ks not
Vol gu
⇒ “1.3 Assembly overview - fuel system”,
ed
by page 254 ara
nte
is
or eo
⇒ “1.4 Checking fuel system forauleaks”,
th page 257 ra
ss c
⇒ “1.5 Filling/bleeding fuel system”, page 257
ce
le
un
pt
an
d
1.1 Schematic overview - fuel system

itte
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erm
ab
ility
ot p
The diesel direct injection system control unit is equipped with an
wit
is n
event memory. Read event memory before and after making re‐
h re
pairs or adjustments.
ole,
spec
t to the co
WARNING
♦ Read through the rules for cleanliness and the instructions
rrectne
for working on the fuel system ⇒ page 8 .
♦ Always follow these rules for cleanliness and instructions
ss
before starting work and while working on the fuel system.
o
cial p
f inform
♦ If components of the fuel system between the tank and the
mer
high-pressure fuel pump are removed or renewed, the fuel
atio
m
system must be filled to be bled ⇒ page 257 . (It is im‐

o
n
c
portant not to allow the high-pressure pump to run while
i
or
n thi
e
still empty.)
t
sd
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To prevent the high-pressure fuel pump from running while it is
yi Co
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empty and to ensure that the engine starts quickly after parts have
C py
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been renewed, it is important to observe the following:
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♦ If fuel system components between fuel tank and fuel high-
agen
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pressure pump are removed or renewed;
♦ If the fuel pump - G6- , a fuel line or the fuel filter is removed
or replaced
♦ If the fuel high-pressure pump is removed or replaced
– Carry out function “Fill/bleed high-pressure pump/fuel system”
⇒ page 257 .
1. Injection system 243

Caddy 2011 ➤
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6-
2 - fuel filter.
❑ Assembly overview -
fuel filter
fuel filter agen
AG. Volkswagen AG d
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3 - High-pressure pump ed by
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❑ After renewing, a first ut
hor eo
fuel filling “must”sbe
s per‐
a ra
c
formed (never allow
ce
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nl
pump to run while dry)
pt
du
an
itte
⇒ page 257 .
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erm
ab
ility
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⇒ page 291
wit
, is n
h re
4 - Fuel metering valve - N290-
hole
spec
❑ Do not open.
es, in part or in w
t to the co
5 - Fuel pressure sender - G
247-
rrectness of i
❑ Installing and removing
⇒ page 316
l purpos
6 - High-pressure accumulator
nf
ercia
7 - Fuel pressure regulating
or
valve - N 276-
m
m
atio
m

o
n in
c
⇒ page 311
or
thi
te
❑ 80 Nm.
sd
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8 - Pressure retention valve

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with fuel return lines

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❑ The fuel return lines
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must not be dismantled. p by
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They can only be renewed together with the pressure retention valve as one unit.
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❑ The non-return valve has the task of maintaining a residual pressure (control volume) of approx. 1 bar
in the fuel return lines.
❑ This residual pressure is required for the control function of the piezo injectors.
❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
❑ The pressure retention valve is installed in the fuel return lines just before the metal return line.
❑ After replacement, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
❑ Check pressure retention valve ⇒ page 285 .
9 - Injectors (piezo injectors)
❑ Injector, cylinder 1 - N30-
❑ Installing and removing ⇒ page 279
244 Rep. gr.23 - Mixture preparation - injection

Caddy 2011 ➤
1.2 Overview of fitting locations - injection

system
Components A to I are not shown in the illustration.
1 - Exhaust gas pressure sen‐

sor 1 - G450-
❑ Fitting location
⇒ page 251
❑ Adaptation is necessary
after this component
has been renewed
⇒ Vehicle diagnostic
tester
❑ Removing and installing olkswage es n
ot g
⇒ page 311 d byV ua
ran
ir se tee
2 - Hall sender - G40- (cam‐ utho
or
shaft position sensor) ss
a ac
ce
e
nl
pt
du
an
⇒ page 251
itte
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ab
❑ Electrical connection for
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Hall sender - G40-
wit
⇒ page 251
, is n
h re
hole
❑ 10 Nm.
spec
es, in part or in w
t to the co
⇒ page 357
3 - Exhaust gas temperature
sender 3 - G495-
rrectness of i
l purpos
⇒ page 252
❑ Electrical connector for
nf
ercia
exhaust temperature
orm
sender 3 - G495-
m
atio
m
⇒ page 253
o
n in
or c
4 - Lambda probe - G39- with

thi
te
sd
a
Lambda probe heater - Z19-

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Prote AG.

Caddy 2011 ➤
⇒ page 252
❑ 50 Nm.
5 - Engine (motor) control unit - J623-
❑ Fitting location ⇒ page 248
7 - Position sender for charge pressure positioner - G581-
8 - Fuel pressure regulating valve - N276-
❑ 80 Nm.
9 - Charge pressure control solenoid valve - N75-
❑ Fitting location of connector ⇒ page 253
10 - Electrical connector
❑ For exhaust gas temperature sender 3 - G495-
❑ For exhaust gas temperature sender 1 - G235- .
❑ For Lambda probe - G39- .
❑ Fitting location ⇒ page 252 agen
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11 - Air mass meter - G70- byV gu
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ed
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❑ Removing and installing ⇒ page 310 ut
ho eo
ra
s a c
s
12 - Radiator outlet coolant - G62-
ce
e
nl
pt
du
an
itte
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ility
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13 - Engine speed sender - G28-

wit
, is n
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hole
❑ 4.5 Nm. spec

es, in part or in w
t to the co
14 - Intake manifold flap motor - V157-
❑ With intake manifold flap potentiometer - G336- .
rrectness of i
❑ If present
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15 - Exhaust gas recirculation cooler changeover valve - N345-

nform
ercia
16 - Pump for exhaust gas recirculation cooler - V400-

m
at

om
ion
c
in t
17 - Throttle valve control module - J338- with throttle valve potentiometer - G69-
or
his
ate

do
priv
cum
❑ Assembly overview - intake manifold ⇒ page 298 .

for
en
ng
t.
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18 - Charge air pressure sender - G31- with intake air temperature sender - G42- rig ht
py by
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Caddy 2011 ➤
19 - Glow plugs AG. Volkswagen AG d

agen oes
❑ Fitting location Volksw⇒ page 250 not
gu
by ara
❑ Glowrispluged
1 - Q10- nte
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❑ Glow
s aut
plug 2 - Q11- ra
c
s
❑ Glow plug 3 - Q12-
ce
le
un
pt
❑ Glow plug 4 - Q13-
an
d
itte
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ility
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20 - Connection of fuel supply line from fuel filter
wit
is n
h re
ole,
spec
21 - Connection of fuel return line to fuel filter
t to the co
22 - Fuel high-pressure pump with fuel metering valve - N290-
rrectne
❑ Do not open fuel metering valve - N290-
ss o
❑ After renewing, a first fuel filling “must” be performed (it is important not to allow the pump to run while it
cial p
f in
is still empty) ⇒ page 257 .
form
mer
atio
om
n
23 - Connection of fuel supply line (high pressure line) to high pressure accumulator
c
i
or
n thi
e

t
sd
iva
o
pr
24 - Fuel temperature sender - G81-

um
r
fo
en
ng
❑ In fuel supply line

t.
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25 - Radiator outlet coolant temperature sender - G83-
c by lksw
cted agen
Prote AG.
26 - Fuel pressure sender - G247-
27 - fuel filter.
❑ Assembly overview - fuel filter
❑ Fuel filter: Renew
A - Fuel system pressurisation pump - G6-
B - Low heat output relay - J359- and high heat output relay - J360-
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
C - Brake light switch - F- and brake pedal switch - F47-
❑ In footwell on brake pedal
D - Clutch position sender - G476-
❑ Only fitted to vehicles with a manual gearbox
E - Accelerator position sender - G79- and accelerator position sender 2 - G185-
F - Exhaust gas recirculation valve 1 - GX5-

Caddy 2011 ➤
G - Exhaust gas temperature sender 1 - G235-

❑ Assembly overview - lambda probes and exhaust gas temperature senders ⇒ page 341 .
H - Exhaust gas temperature sender 4 - G648-
❑ Assembly overview - lambda probes and exhaust gas temperature senders ⇒ page 341 .
I - particulate filter
❑ Secured to underbody
❑ Shared component with a catalytic converter
❑ Adaptation is necessary after this component has been renewed
Carry out adaptation after renewing exhaust gas pressure sensor

1 - G450- and/or particulate filter ⇒ Vehicle diagnostic tester.
Fitting location of engine control unit - J623-
Engine control unit can be found in plenum chamber. agen
AG. Volkswagen AG d
oes
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Removing and installing ⇒ page 321 ed byV gu
ara
ris nte
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
ab
ility
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wit
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Accelerator position sender - G79- and accelerator position send‐
h re
hole
er 2 - G185-
spec
es, in part or in w
Removing and installing
t to the co
Note
rrectness of i
l purpos
The accelerator pedal position sender - G79- and accelerator

pedal position sender 2 - G185- are integrated in the accelerator
pedal module and cannot be replaced singly.
nf
ercia
orm
m
atio
om
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te
sd
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rig ht
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cted agen
Prote AG.

Caddy 2011 ➤
Brake light switch - F- and brake pedal switch - F47- -1-

Integrated functions: Clutch pedal switch for engine starting -
F194- and clutch pedal switch - F36- (only in the case of manual
gearboxes)
Clutch position sender - G476-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
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d
itte
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pe
ility
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Fuel system pressurisation pump - G6-
hole
spec
es, in part or in w
Removing and installing
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
en
ng
t.
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Cop py
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cted agen
Prote AG.

Caddy 2011 ➤
Locations
2 - Glow plug 1 - Q10-
6 - Fuel pressure regulating valve - N276-
8 - Throttle valve control module - J338- with throttle valve po‐
tentiometer - G69-
9 - Connection of fuel supply line from fuel filter
10 - Connection of fuel return line to fuel filter
11 - Fuel metering valve - N290-
12 - Connection of fuel supply line (high pressure line) to high
pressure accumulator
13 - Fuel temperature sender - G81-
Pump for exhaust gas recirculation cooler - V400-

2 - Pump for exhaust gas recirculation cooler - V400-
♦ On front of engine
Assembly overview ⇒ page 211
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
Charge air pressure sender - G31- with sintake
s air temperature
sender - G42- -1-
ce
e
nl
pt
du
an
itte
1- Charge air pressure sender - G31- with intake air tempera‐

y li
erm
ab
ture sender - G42-

ility
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♦ On air pipe on right

wit
, is n
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hole
Removing and installing ⇒ page 239

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
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pyri by
Vo
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by
cted agen
Prote AG.

Caddy 2011 ➤
Hall sender - G40-

♦ Next to toothed pulley of camshaft -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
tho eo
au ra
ss c
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nl
pt
du
Connector -1- for Hall sender - G40-
an
itte
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erm
ab
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
Locations
m
at
1- Exhaust gas pressure sensor 1 - G450-
om
ion
c
in t
r
2- Fuel pressure sender - G247-

o
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ate
do
priv
cum
for
en
ng
t.
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Cop py
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Radiator outlet coolant temperature sender - G83-

2 - Radiator outlet coolant temperature sender - G83-
♦ In coolant pipe on right above the alternator.

Caddy 2011 ➤
Engine speed sender - G28-

1- Engine speed sender - G28-
2- Sender wheel
Exhaust gas recirculation cooler changeover valve - N345-

♦ On front left of intake manifold
Components on engine
1- Exhaust gas pressure sensor 1 - G450-
2- Exhaust gas temperature sender 3 - G495-
3- Lambda probe - G39-
AG. Volkswagen AG d
agen o
4- Position sender for charge
yV
olks pressure positioner - G581-
w es n
ot g
b ua
ed ran
5- Injectors (N30 tohoN33)
ris tee
t or
au ac
6- Glow plugs (Q10
ss to Q13)
ce
e
nl
pt
7- Fuel pressure sender - G247-

du
an
itte
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erm
ab
ility
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Installation locations and plug-in connections

wit
, is n
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1- Electrical connector for exhaust temperature sender 3 -

hole
spec
G495-
es, in part or in w
t to the co

G235-
3- Electrical connector for Lambda probe - G39-
rrectness of i
1 - Electrical connector for charge pressure control solenoid valve

l purpos
- N75-
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
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Vo
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cted agen
Prote AG.

Caddy 2011 ➤
Location and connector

G648-
Charge pressure control solenoid valve - N75-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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nl
pt
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Coolant temperature sender - G62- -1-

ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
Components on rear of engine

om
n in
or c
1- Lambda probe - G39-

thi
te
sd
iva
2- Exhaust temperature sender 1 - G235- in the turbocharger

o
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f
en
ng
3- Exhaust gas temperature sender 4 - G648-

t.
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op py
4- Vacuum unit for exhaust gas recirculation cooling system
. C rig
ht ht
rig by
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5- Exhaust gas recirculation valve 1 - GX5-
co lksw
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cted agen
Prote AG.
6- Electrical connector on exhaust gas recirculation valve 1 -
GX5-

Caddy 2011 ➤
1.3 Assembly overview - fuel system
WARNING

for working on the fuel system.
Caution
To prevent the high-pressure fuel pump from running while it

is empty and to ensure that the engine starts quickly after parts
have been renewed, it is important to observe the following:
♦ If fuel system components between fuel tank and fuel
high-pressure pump are removed or renewed;
♦ Basic setting “Checking fuel pre-supply pump” must be
carried out to bleed fuel system.
♦ If a fuel pump, fuel line (between fuel tank and fuel high-
pressure pump) or fuel filter is removed or renewed
♦ Basic setting “Testing fuel pre-supply pump” must be car‐
ried out »once« before first starting engine.
♦ If the high-pressure fuel pump is removed or renewed, the
basic setting “Checking fuel system pressurisation pump”
must be performed »three times« before the engine is
started for the first time.
♦ Performing first fuel filling after installing high-pressure
pump ⇒ page 257 . wage
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d by ara
e nte
ris
tho eo
au ra
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ss
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nl
pt
du
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itte
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erm
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ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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ng
t.
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Cop py
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pyri by
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cted agen
Prote AG.

Caddy 2011 ➤
1 - Fuel return pipe

❑ Flexible
❑ To fuel tank
❑ The fuel return line must
not be kinked, damaged
or blocked.
❑ The fuel return lines
must not be dismantled.
❑ Renew O-ring only if
necessary.
❑ The pressure retention
valve maintains a resid‐
ual pressure in the fuel
return lines.
❑ This residual pressure is
required for the control
function of the piezo in‐
jectors.
❑ Check pressure reten‐
tion valve ⇒ page 285 .
valve - N276-
⇒ page 311
❑ 80 Nm.
❑ After renewing, readapt
learnt values ⇒ Vehicle
diagnostic tester
❑ Rigid.
4 - Bolt agen
AG. Volkswagen AG d
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❑ 10 Nm. d byV
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5 - High-pressure pump ut
ho eo
ra
a
❑ With fuel metering valve - N290- (do not open) ss c
ce
e
nl
❑ After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty)
pt
du
an
⇒ page 257 .
itte
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erm
ab

ility
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wit
6 - Bolt
, is n
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hole
❑ 20 Nm +180°
spec
es, in part or in w
7 - Hub
t to the co
❑ With sender ring

❑ Use counterhold - T10051- to loosen and tighten.
rrectness of i
❑ To remove, use puller - T40064- .

l purpos
8 - Nut
❑ 95 Nm.
nf
ercia
or
9 - Toothed belt pulley on high-pressure pump

m
m
atio
m
10 - Bolt
o
n in
or c
thi
❑ 20 Nm +45°
te
sd
iva
o
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11 - Bolt
rp
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f
en
ng
❑ 10 Nm.
t.
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Cop py
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rig ht
py by
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by lksw
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255
Prote AG.
1. Injection system
Caddy 2011 ➤
agen
AG. Volkswagen AG d
o w es n
olks ot g
yV ua
12 - High-pressure line ris
ed
b ran
tee
ho
❑ Between high-pressure pump and fuel rail au
t or
ac
ss
❑ Install so that component is not under tension
ce
le
un
pt
❑ For installation, the 17 mm tool insert - V.A.G 1331/6- and the support sleeve - T10411- are needed.
an
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itte
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Note
pe
ility
ot
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♦ The high-pressure line may be
h re
hole
re-used after the following
spec
checks:
es, in part or in w
t to the co
♦ Check taper seat of high-pres‐
sure line for deformation and
cracks.
rrectness of i
♦ The inside of the line must not be
l purpos
deformed, constricted or dam‐

aged.
nform
ercia
♦ Corroded lines should no longer

m
be used.
a
com
tion in
r
❑ 28 Nm.
te o
thi
s
iva
do
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cum
fo
❑ 100 Nm.
en
ng
t.
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❑ Removing and installing ⇒ page 316 Cop py
ht. rig
rig ht
14 - High-pressure accumulator py by
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agen
Prote AG.
15 - Bolt
❑ 22 Nm.
16 - High-pressure lines
❑ When loosening and tightening, counterhold on the injector connection
❑ Between high pressure accumulator and injectors (piezo injectors)
❑ Do not interchange
❑ Install so that component is not under tension
Note
♦ Observe cylinder-specific mark‐

ings if reusing high-pressure
lines.
♦ The high-pressure lines may be
re-used after the following
checks:
♦ Check taper seat of respective
high-pressure line for deforma‐
tion and cracks.
♦ The inside of the line must not be
deformed, constricted or dam‐
aged.
♦ Corroded lines should no longer
be used.
❑ 28 Nm.
17 - Gasket
❑ Renew if damaged ⇒ page 114 .

Caddy 2011 ➤
18 - Gasket
❑ Renew if damaged ⇒ page 114 .
❑ The following components and seals/O-rings must be renewed each time on removal/installation: “bolt
for clamping piece”, “copper seal”, “O-ring of injector bore” and “retaining clip for return connection”.
❑ The following components must also be renewed when an injector is replaced: “bolt for clamping piece”
❑ Before re-using “high-pressure line”, perform visual check of taper seats for damage such as transverse
scores or corrosion. Always replace them if damaged.
❑ If removed piezo injectors, high-pressure lines and clamping pieces are to be reinstalled, they must
always be re-fitted in their original positions (i.e. on the same cylinder).
20 - Bolt
❑ Initial specified torque: 2 Nm
❑ 8 Nm +270°
21 - O-ring for fuel return lines
❑ Renew O-ring only if necessary.
❑ The following component must be renewed any time the fuel return line is removed and installed: “return
line retaining clip”.
1.4 Checking fuel system for leaks

– Clean all removed and re-installed fuel connections with brake
cleaner and then dry them.
– Allow engine to idle for 5 minutes without depressing acceler‐
ator pedal. Then, switch engine off. Fuel system will be bled
automatically. wage
e
ks s no
Vol t gu
– Check entireedfuel
by system for leaks . ara
is nte
or
Renew theautaffected
h component if leakage still occurs after eo
rtight‐
ac
ening to sthe
s correct torque.
ce
le
un
pt
– Then road test the vehicle, accelerating to full throttle at least

an
d
itte
once. Then check high-pressure section of fuel system again

y li
rm
ab
for leakage.
pe
ility
ot
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Note
hole
spec
es, in part or in w
t to the co
If there is still air in the fuel system, the engine can change to
emergency running mode during road test. Then, switch off en‐
gine and clear event memory. Then continue with a road test.
rrectness of i
1.5 Filling/bleeding fuel system

l purpos

nform
ercia

m
a
com
tion in
Caution
r
te o
thi
s
iva
do
After new or removed parts such as the fuel filter or fuel lines
r
rp
cum
fo
have been fitted, the high-pressure pump must be filled with

en
ng
t.
fuel before the engine is started for the first time. It is essential
yi Co
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not to allow the high-pressure pump to run while still empty.
C py
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Prote AG.

Caddy 2011 ➤
4-cylinder diesel engine (1.6walgengine,
en AG. V common
olkswagen AGrail) - Edition 09.2016
doe
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ris
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Note au
t ra
c
ss
ce
e
♦ When installing the high-pressure pump, it is essential to en‐ nl
pt
du
an
sure that no dirt enters the fuel system.
itte
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erm
ab
♦ Only remove sealing plugs immediately prior to installation of
ility
ot p
fuel lines.
wit
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♦ Vehicle must have fuel.
hole
spec
es, in part or in w
t to the co
To bleed/fill the fuel system, it is necessary to meet these condi‐
tions.
• Vehicle must have fuel.
rrectness of i
• Fuel system temperature ≥ 15 °C
l purpos
• Temperature of fuel ≥ 15 °C
nf
ercia
Proceed as follows to fill high-pressure pump and fuel system with
orm
fuel:
m
atio
om
n in
c

or
thi
te
sd
– Connect ⇒ Vehicle diagnostic tester and, depending on soft‐
iva
o
r
ware version, perform function “Bleed fuel system” or “Fill/

rp
cu
o
m
bleed fuel system”.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
yri
Note
p by
o Vo
by c lksw
cted agen
Prote AG.
♦ The fuel pumps will now be actuated for a total of three mi‐
nutes. The process must not be terminated prematurely.
♦ There could still be air bubbles in the fuel system after the
bleeding procedure.
– Start engine and visually inspect fuel system for leaks.
Caution
Do not carry out starting attempts for longer than 15 seconds.

If engine does not start, repeat bleeding process twice.
– After filling fuel system and successfully starting engine, allow

it to run for a few minutes at a moderate speed. Switch off
engine.
– Check fuel system for leaks.
– Read out event memory and, if necessary, clear event mem‐
ory entry.
– Then, road-test the vehicle for more than 20 km with full throttle
acceleration at least once. Then check high-pressure section
of fuel system again for leakage.
Note
emergency running mode during road test. Then, switch off en‐
gine and clear event memory. Then continue with a road test.
– Read event memory.

Caddy 2011 ➤
2 Vacuum system
⇒ “2.1 Connection diagram - vacuum system”, page 259
⇒ “2.2 Checking vacuum system”, page 260
⇒ “2.2.1 Checking non-return valve and vacuum hoses”,
page 261
⇒ “2.2.2 Checking vacuum reservoir and vacuum hoses”,
page 262
⇒ “2.2.3 Checking exhaust gas recirculation cooler changeover
valve N345 and vacuum hoses”, page 263
⇒ “2.2.4 Checking exhaust gas recirculation cooler changeover
valve”, page 264
⇒ “2.2.5 Checking charge pressure control solenoid valve N75
and vacuum hoses”, page 265 AG. Volkswagen n AG do
ks wage es n
⇒ “2.2.6 Checking vacuum unit on turbocharger andy vacuum
Vol ho‐ ot g
ua
ses”, page 266 ir se
d b ran
tee
ho
ut or
2.1 Connection diagram - vacuum system ss
a ac
ce
e
nl
pt
du
an
itte
Caution
y li
erm
ab
ility
ot p
Do not kink, twist or crush the vacuum lines when routing vac‐
wit
, is n
uum lines. This may cause breakdowns.
h re
hole
spec
Push all hoses onto stop or at least 10 mm onto the respective
es, in part or in w
connection.
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.
2. Vacuum system 259

Caddy 2011 ➤
1 - Pressure canister
❑ On turbocharger.
❑ With position sender for
charge pressure posi‐
tioner - G581- .
2 - Charge pressure control
solenoid valve - N75-
⇒ page 231
3 - Silencer
4 - Air filter
5 - To brake servo.
6 - Connection piece
❑ On vacuum pump AG. Volkswagen AG d
agen oes
lksw not
7 - Non-return valve by Vo gu
ara
d
❑ Observe installation po‐ rise nte
ho eo
sition s aut ra
c
s
ce
e
nl
pt
du
cooler changeover valve -
an
itte
y li
N345-
erm
ab
ility
ot p
9 - Cylinder head cover
wit
, is n
❑ With vacuum reservoir
h re
hole
spec
10 - Vacuum unit
es, in part or in w
t to the co
❑ For changeover for ex‐
haust gas recirculation
cooler.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
c
2.2 Checking vacuum system

or
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
cted agen
Prote AG.

Caddy 2011 ➤
♦ Hand operated vacuum pump - VAS 6213-
Caution
Do not kink, twist or crush the vacuum lines when routing vac‐
uum lines. This may cause breakdowns.
Push all hoses onto stop or at least 10 mm onto the respective
connection.
2.2.1 Checking non-return valve and vacuum

hoses
Test sequence
– Pull off vacuum hose -2- from connection. Seal open end of
hose with suitable plug from engine bung set - VAS 6122- .
Note agen
AG. Volkswagen AG d
oes
olksw not
y V gu
Do not use screws or threaded ise bolts.
d b ara
r nte
tho eo
au ra
– Pull off vacuum hoses -1- from connection.
s c
ce
le
un
pt
– Connect hand vacuum pump - VAS 6213- to pulled-off end of

an
d
itte
vacuum hose -1- and generate a partial vacuum of 0.6 bar.

y li
rm
ab
pe
ility
– Observe pressure gauge of hand vacuum pump - VAS 6213-

ot
wit
for approx. 30 seconds.

, is n
h re
hole
• Vacuum must not drop.

spec
es, in part or in w
If vacuum drops:
t to the co
– Renew leaking vacuum hose or non-return valve.

rrectness of i
If pressure does not drop:

l purpos
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
If the non-return valve functions properly, a clear hiss is audible
nform
ercia
when vacuum in vacuum hose is released.

m
– Reconnect vacuum hose to connecting piece and vacuum

com
tio
pump.
n in
r
te o
thi
s
iva
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cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
2.2.2 Checking vacuum reservoir and vacuum

hoses olks
wage
es n
o
yV t gu
Test sequence db ara
rise nte
tho eo
– Pull off vacuum hose -arrow- from connection.
ss
au ra
c
ce
e
– Connect hand vacuum pump - VAS 6213- to removed vacuum
nl
pt
du
an
hose -arrow- and generate a partial vacuum of 0.6 bar.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
If vacuum drops:
es, in part or in w
t to the co
rrectness of i
l purpos
– Pull off vacuum hose -2- from cylinder head cover -1-.
– Seal open end of hose with suitable plug from engine bung set
nf
ercia
o
- VAS 6122- .
rm
m
atio
om
n in
or c
Note
thi
te
sd
iva
o
r
Do not use screws or threaded bolts.

rp
cu
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f
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ng
t.
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op
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum C py
ht. rig
reservoir and generate a partial vacuum of 0.6 bar. rig ht
py by
co Vo
by lksw
– Observe pressure gauge of hand vacuum pump - VAS 6213- Prote
cted AG.
agen
If vacuum drops:
– Renew vacuum hose.
– Connect hand vacuum pump - VAS 6213- with vacuum hose
from -VAS 6213- to cylinder head cover and generate a partial
vacuum of 0.6 bar.
If vacuum drops:
– Renew cylinder head cover ⇒ page 109 .
If the vacuum reservoir in the cylinder head cover works properly,
a hiss will be clearly audible when normal pressure is restored in
the vacuum hose.
– Reconnect vacuum hose to T-piece and cylinder head cover.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
c
Caddy 2011 ➤
s
ce
le
un
pt
an
d
itte
2.2.3 Checking exhaust gas recirculation
y li
rm
ab
pe cooler changeover valve - N345- and
ility
ot
wit
, is n
vacuum hoses
h re
hole
spec
Test sequence
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
If vacuum drops:
a
com
tion in
– Unhook exhaust gas recirculation cooler changeover valve -
r
te o
thi
N345- from bracket on intake pipe.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi
– Pull off vacuum hose -arrow- on bottom connection of exhaust
Co
op py
gas recirculation cooler changeover valve - N345- . t. C rig
gh ht
pyri by
o Vo
by c lksw
cted agen
- VAS 6122- . Prote AG.
Note
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum

reservoir and generate a partial vacuum of 0.6 bar.
If vacuum drops:
from -VAS 6213- to exhaust gas recirculation cooler change‐
over valve - N345- and generate a partial vacuum of 0.6 bar.
If vacuum drops:
– Renew exhaust gas recirculation cooler changeover valve -
N345- .
– Reconnect vacuum hose on T-piece and on exhaust gas re‐
circulation cooler changeover valve - N345- .

Caddy 2011 ➤
2.2.4 Checking exhaust gas recirculation

cooler changeover valve
Test sequence
– Unhook exhaust gas recirculation cooler changeover valve -
N345- from bracket on intake pipe.
– Pull off vacuum hose -arrow- on middle connection of exhaust
gas recirculation cooler changeover valve - N345- .
If vacuum drops:
– Raise vehicle on lift.
– Pull off heat protection -2- from vacuum servo element.

– Pull off vacuum hose -1- from vacuum servo element.
- VAS 6122- .
AG. Volkswagen AG d
agen oes
olksw not
V gu
Note d by ara
ise nte
or eo
h
ut ra
Do not use screws or threaded bolts. ss a c
ce
le
un
pt
an
d
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum

itte
y li
reservoir and generate a partial vacuum of 0.6 bar.
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
If vacuum drops:
rrectness of i
l purpos

from -VAS 6213- to vacuum servo element of exhaust gas re‐
circulation cooler changeover valve and generate a partial
nform
ercia
vacuum of 0.6 bar.

m
a
com
ti

on in

r
te o
thi
s
iva

do
r
rp
cum
fo
If vacuum drops:
en
ng
t.
yi Co
op
– Renew exhaust gas recirculation cooler.
C py
t. rig
gh ht
yri by
op Vo
by c lksw
cted agen
Prote AG.
– Reconnect vacuum hose on exhaust gas recirculation cooler
and on exhaust gas recirculation cooler changeover valve -
N345- .

Caddy 2011 ➤
2.2.5 Checking charge pressure control sole‐

noid valve - N75- and vacuum hoses
Test sequence
case.
– Pull off vacuum hose -arrow- on bottom connection of charge

pressure control solenoid valve - N75- . gen AG
. Volkswagen AG
d wa oes
olks not
– Seal open end of hose with suitable plug from
db
y V engine bung set gu
ara
- VAS 6122- . o
ir se nte
eo
th
au ra
c
ss
ce
le
Note
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
s
s o
cial p
f i
nform
mer
If vacuum drops:
atio
om
n
c

i
or
n thi
te
sd
a

iv
o
pr
cum
r
fo

en
ng
t.
from -VAS 6213- to bottom connection of charge pressure op
yi Co
control solenoid valve - N75- and generate a partial vacuum
C py
t. rig
gh
of 0.6 bar.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
If vacuum drops:
– Renew charge pressure control solenoid valve - N75-
⇒ page 231 .
– Reconnect vacuum hose on T-piece and on charge pressure
control solenoid valve - N75- .

Caddy 2011 ➤

. Volkswagen AG
bocharger. -arrow-. swa
gen AG does
olk not
yV 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
2.2.6 Checking vacuum unit on turbocharger
t to the co
and vacuum hoses
rrectness of i
Test sequence
l purpos
case.
nf
ercia
orm
m
atio
om
n in
c
or
thi
e

t
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.
– Pull off vacuum hose -arrow- on middle connection of charge
pressure control solenoid valve - N75- .
- VAS 6122- .
Note

Caddy 2011 ➤
– Open bracket -2- and unhook vacuum hose -1-.

– Pull off vacuum hose -1- from vacuum unit on turbocharger.
• Vacuum must not drop. n AG. Volkswagen AG do
lkswage es n
If vacuum drops: byV
o ot g
ua
d ran
ir se
– Renew vacuum hose.utho tee
or
s a ac
s
ce
le
un
pt
an
d
itte
y li
from -VAS 6213- to vacuum unit on turbocharger and generate
rm
ab
a partial vacuum of 0.6 bar.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
If vacuum drops:
– Replace turbocharger ⇒ page 226 .
rrectness of i
l purpos
nform
ercia
– Reconnect vacuum hose on vacuum unit of turbocharger and

on charge pressure control solenoid valve - N75- .
m
a
com
tion in
r

te o
thi

s
iva
do
bocharger. -arrow-.
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.

Caddy 2011 ➤
3 Injectors/high-pressure accumulator
(rail)
. Volkswagen AG
⇒ “3.1 Overview - fuel return lines”, page 268 kswagen AG does
not
ol
yV gu
⇒ “3.2 Assembly overview - injectors”, page
ised b 269 ara
nte
r
ho eo
⇒ “3.3 Removing and installing high-pressure
sa
ut lines”, page 269 ra
c
s
⇒ “3.4 Removing and installing fuel rail”, page 275
ce
le
un
pt
an
d
itte
⇒ “3.5 Removing and installing injectors”, page 279
y li
erm
ab
ility
⇒ “3.6 Adapting correction values for injectors”, page 284
ot p
wit
is n
⇒ “3.7 Replacing O-ring of fuel return lines”, page 285
h re
ole,
spec
⇒ “3.8 Check pressure retention valve in fuel return line”,
page 285
t to the co
⇒ “3.9 Checking return flow rate of injectors at starter speed”,
page 287
rrectne
⇒ “3.10 Testing injectors”, page 288
s
3.1 Overview - fuel return lines
s o
cial p
f inform
mer
1 - 0.5 bar fuel return line, low-
atio
m
pressure fuel system

o
n
c
i
or
n
⇒ Item 1 (page 255)
thi
te
sd
a
❑ Flexible
iv
o
pr
cum
r
❑ With pressure retention

fo
en
ng
valve
t.
yi Co
Cop py
.
2 - 6.0 bar fuel return line, low-
ht rig
rig ht
by
pressure fuel system copy Vo
by lksw
⇒ Item 1 (page 255) cted agen
Prote AG.
❑ Flexible
❑ With pressure retention
valve
3 - 0.5 bar fuel return lines, low-
❑ Rigid.
4 - 6.0 bar fuel return lines, low-
❑ Rigid.

Caddy 2011 ➤
3.2 Assembly overview - injectors
1 - Injectors
❑ Piezo injectors
WARNING
Only cleaning set - VAS
6811- may be used for
cleaning the sealing sur‐
face of the injector bore.
For detailed information
on how to use the clean‐
ing set as well as the or‐
der in which its compo‐
nents are applied, refer
to the ⇒ operating man‐
ual provided with the
cleaning set - VAS
6811- .
2 - Bolt AG. Volkswagen AG d

agen oes
❑ Renew after removal olksw not
y V gu
d b ara
❑ Initial specified torque: orise nte
eo
2 Nm auth
ra
ss c
❑ 8 Nm +270°
ce
le
un
pt
an
3 - High-pressure fitting
d
itte
y li
erm
ab
❑ Counterhold when loos‐
ility
ot p
ening the high-pressure

lines. wit
is n
h re
ole,
4 - Return lines retaining clip

spec

t to the co
❑ Grease the retaining clip

lightly before installing
the injector.
rrectne
5 - Copper washer
ss

o
cial p
f in
6 - O-ring
form
mer

atio
om
❑ For renewing, use assembly sleeve - T10377-

c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
3.3 Removing and installing high-pressure

en
ng
t.
yi Co
lines Cop py
t. rig
gh ht
yri by
⇒ “3.3.1 Removing high-pressure lines between fuel rail and in‐
cop Vo
by lksw
cted
jectors”, page 271
agen
Prote AG.
⇒ “3.3.2 Removing high-pressure line between fuel rail and high-

pressure pump”, page 272
⇒ “3.3.3 Installing high-pressure lines”, page 273
3. Injectors/high-pressure accumulator (rail) 269

Caddy 2011 ➤
AG. Volkswagen AG d
♦ Torque wrench (5 to 50 Nm) - V.A.G 1331- 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
♦ Ratchet wrench - V.A.G 1331/1-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
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f
en
ng
t.
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Cop py
t. rig
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pyri by
♦ Tool insert 17 mm - V.A.G 1331/6-
co Vo
by lksw
cted agen
Prote AG.
♦ Engine bung set - VAS 6122-

Caddy 2011 ➤
♦ Socket - T40055-
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
♦ Support sleeve - T10411- s aut ra
c
s
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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
3.3.1 Removing high-pressure lines between
nform
ercia
fuel rail and injectors

m
a
com
tion in
– Remove motor cover panel ⇒ page 47 .
r
te o
thi
s
iva
do
r
rp
c
Caution
um
fo
en
ng
t.
yi Co
op
Ensure absolute cleanliness. There should be no dirt in the C py
t. rig
disconnected fuel return lines or the open connections on the
gh ht
pyri by
injectors under any circumstances.
o Vo
by c lksw
cted agen
Prote AG.
Protect open fuel connections from dirt entrainment using suit‐
able methods under all circumstances.
Used injectors may only be re-installed on the same cylinder.
Note
♦ The fluff-free cloth and the brake cleaner can be ordered in ⇒

ServiceNet; Workshop Equipment; Techno Equipment Cata‐
logue; BMK Consumables .
♦ Whenever work is done on the fuel system, ensure cleanliness
and do the work carefully. The fuel system reacts sensitively
to the ingress of dirt.
– Before removing, clean the parts thoroughly all over with brake
cleaner and fluff-free cloth.
Preferable order for disconnecting high-pressure lines cylinder
4-3-2-1

Caddy 2011 ➤
– To disconnect the high-pressure lines, counterhold the high-

pressure fitting -A- on the injectors.
– Remove high-pressure line between fuel rail and injectors.
– Then only loosen the high-pressure line between fuel rail and
high-pressure pump -3-.
– Place removed parts on a clean, fluff-free surface and cover
them.
A clean plastic bag can also be used.
– Ensure that removed parts are not placed anywhere unpro‐
tected.
– Use a vacuum-type cleaner to remove dirt from taper seat on
high-pressure accumulator.
– Seal all connections with clean plugs from engine bung set -
VAS 6122- .
3.3.2 Removing high-pressure line between

fuel rail and high-pressure pump
Caution
Ensure absolute cleanliness. There should be no dirt in the

disconnected fuel return lines or the open connections on the n AG. Volkswagen AG do
injectors under any circumstances. olks
wage es n
o V t gu
by
Protect open fuel connections from dirt entrainment using
ris suit‐
ara
ed nte
able methods under all circumstances. ut
ho eo
ra
a c
ss
Used injectors may only be re-installed on the same cylinder.
ce
le
un
pt
an
d
itte
y li
rm
ab
– Unscrew bolts -1 and 2-, and remove engine lifting eyes -3-.
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
272
c by lksw
cted agen
Rep. gr.23 - Mixture preparation - injection Prote AG.
Caddy 2011 ➤
– Unscrew union nuts -1 and 4- and remove high-pressure line

-2-.
– Place removed parts on a clean, fluff-free surface and cover
them.
A clean plastic bag can also be used.
– Ensure that removed parts are not placed anywhere unpro‐
tected.
– Seal all connections with clean plugs from engine bung set -
VAS 6122- .
3.3.3 Installing high-pressure lines
Caution
To position injection lines more easily and stress-free, loosen

high pressure accumulator (rail) and injectors and shift slightly.
The lines must never be bent or tensioned. Tension would oth‐
erwise cause the respective line to break in the long-term.
Note
♦ Making use of a setting tool to adjust the high pressure or in‐

jectors (piezo injectors) is not permissible.
♦ Observe cylinder-specific markings if reusing high-pressure
lines.
♦ The high-pressure lines may be re-used after the following
checks:
AG. Volkswagen AG d
♦ If the taper seal of respective high-pressure line
olks
whas
agen been oes
not
checked for deformation and cracks. d by V gu
ara
rise nte
♦ The inside of the line must not be deformed,
utho constricted or eo
ra
damaged. ss a c
ce
e
nl
♦ Corroded lines should no longer be used.

pt
du
an
itte
y li
erm
ab
ility
ot p
Caution
wit
, is n
h re
hole
When installing a new short engine, it is compulsory to fix and

spec
tighten the clamping jaws of the injectors to the specified torque

es, in part or in w
t to the co
after installing the high-pressure lines ⇒ Item 20 (page 257) 20.

Clamping jaws are only secured »hand-tight« for setting the
injectors while installing high-pressure lines. Non-observance
of these notes may lead to damage to engine.
rrectness of i
l purpos

nf
ercia
orm
– Clean fuel line and head of line using cold cleaning solvent
m
atio
m
and dry using compressed air.

o
n in
or c
thi
– Moisten union nut thread with fuel.

te
sd
iva
o
r
– Fit the injection lines from high-pressure accumulator to injec‐

rp
cu
o
tor by hand first, only tighten union nuts by hand.

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
273
cted agen
Prote AG.
3. Injectors/high-pressure accumulator (rail)
Caddy 2011 ➤
Next install high-pressure line from high-pressure pump to high-

pressure accumulator.
– To install high-pressure line between high-pressure pump and
high-pressure accumulator, slide support sleeve -T10411- on‐
to fuel pressure sender - G 247- .
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♦ The lifting eye (for engine mounting) must be movable in order
to fit union nut on high-pressure pump; loosen bolts -4- to do
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♦ Support sleeve -T10411- specifies the correct distance be‐

tween fuel pressure sender - G 247- and high-pressure line.
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– Only tighten union nuts on high-pressure line from high-pres‐
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sure pump to high-pressure accumulator by hand.

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– Tighten high-pressure lines on high-pressure accumulator and C py
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injector to specified torque ⇒ Item 16 (page 256) 16. rig ht
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– To tighten injector lines, use torque wrench - V.A.G 1331- with Prote
cted AG.
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ratchet - V.A.G 1331/1- and 17 mm socket - T40055- .
– Tighten high pressure line -2- between high pressure pump
and high pressure accumulator first at high pressure pump
-4- and then at high pressure accumulator -1-.

Caddy 2011 ➤
– Tighten bolt -3- for retainer for high-pressure line.

Torque settings
♦ ⇒ page 269
♦ ⇒ page 254
♦ Firmly screw lifting eye in ⇒ page 53 .
– Remove support sleeve - T10411- .
– Reconnect connector to fuel pressure sender - G247- .
– Press return line connections carefully onto injectors (check
seal for damage before connecting return line). You should
hear them click into place.
– Engage pressure retention valve in retainer provided on the
cylinder head cover.
– Bleed fuel system with ⇒ Vehicle diagnostic tester.
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♦ After renewing the injectors,
aut
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ra
rection values” ⇒ Vehicle
s diagnostic tester. When doing this,
s c
select “Reading / adapting” correction values.
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le
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♦ Never allow the high-pressure pump to run dry under any cir‐
y li
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ab
cumstances. If the low-pressure section of the fuel system was
pe
ility
also opened (between fuel tank and high pressure pump), the
ot
wit
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fuel system must be filled ⇒ page 257 .
h re
hole
spec
– Filling fuel system ⇒ page 257 .
es, in part or in w
t to the co
– Check high pressure lines and connections for leaks. To do
this, allow engine to run at idle for several minutes without
pressing accelerator pedal.
rrectness of i
– Switch off ignition.
l purpos
– Check the complete fuel system and return line connections

for leaks.
nform
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– Wipe the connections with a clean cloth and check whether

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there is fuel on the cloth.

ion in
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• Renew the affected component if leakage still occurs after

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tightening to the correct torque.

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• Tightening threaded connections further is not permissible.

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– Then test drive the vehicle, accelerating to full throttle at least C py
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once. rig ht
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– Then check high-pressure section of fuel system again for Prote
cted AG.
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leakage.
Note
emergency running mode during road test. Switch off engine and
clear event memory ⇒ Vehicle diagnostic tester. Then continue
with a road test.
3.4 Removing and installing fuel rail


Caddy 2011 ➤
♦ Pliers - 3314-
♦ Ratchet wrench - V.A.G 1331/1-
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♦ Tool insert 17 mm - V.A.G 1331/6-

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rig ht
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Caddy 2011 ➤
♦ Socket - T40055-

Removing
WARNING
If the fuel pressure regulating valve - N276- has been renewed,

kswagen AG
the learnt values for the fuel system
wa must
gen AG. Volbe reset ⇒doVehicle
es n
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diagnostic tester. by
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♦ Read rules for cleanliness and the instructions for working

erm
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on the fuel system ⇒ page 8 .

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es, in part or in w
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– Remove fuel high-pressure line -2- ⇒ page 269 .

rrectness of i
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277
Prote AG.
3. Injectors/high-pressure accumulator (rail)
Caddy 2011 ➤
Note
In order to undo the union nuts on the high-pressure pump, the

lifting eye must be movable. To ensure this, loosen the bolts -4-.
– Open cable guide catches -arrows- to lay wiring harness to

side.
Caution

– Position pliers - 3314- with groove -arrow A- on support sleeve

shoulder -arrow B-.
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– Carefully pull connectors off glow plugs in

itte
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-direction of arrow-.
ab
ility
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Prote
278
AG.
Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
– Pull off electrical connectors -1 and 4-.

– Pull off fuel return hose -2-.
– Detach electrical connectors -1-, -6- and -7-.
Caution
♦ Mark high-pressure lines to indicate which ones belong to

which cylinders. Injectors must always be re-installed on
the same cylinders.
♦ Observe rules for cleanliness when working on the injec‐
tion system. n AG. Volkswagen AG ge does
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♦ The open connections mustbybe
Volsealed immediately with a
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– Remove high pressure lines between injectors (piezo injec‐

nl
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tors) and high pressure accumulator ⇒ page 269 .

an
itte
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Note h re
hole
spec
In order to release the high-pressure lines, use the connecting

es, in part or in w
t to the co
piece -A- as a counterhold.
– Place the removed high-pressure lines on a clean fluff-free

rrectness of i
cloth.
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– Remove high pressure accumulator. To do this, unscrew the

n
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two bolts -arrows-.

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• It must be possible to move the rail so the hoses can be fitted
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Torque settings Prote AG.
♦ ⇒ “1.3 Assembly overview - fuel system”, page 254

♦ ⇒ “3.2 Assembly overview - injectors”, page 269
3.5 Removing and installing injectors

Caddy 2011 ➤

equipment required
♦ Tapered roller bearing pull‐
er - T10055-
♦ Assembly sleeve - T10377-
AG. Volkswagen AG d
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♦ Socket - T40055- olksw
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♦ Torque wrench (5 to orise nte
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♦ Ratchet wrench - V.A.G
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1331/1-
an
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♦ Support sleeve - T10411-
ab
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Cop py
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rig ht
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♦ Injector remover - T10402-
Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. gr. 66 ; Mouldings and trims; Removing and
installing plenum chamber cover
exterior; Rep. gr. 50 ; Plenum chamber bulkhead .

Caddy 2011 ➤
WARNING

– Disconnect connectors -1- from injectors to be removed.

– Unscrew high pressure line between fuel rail and injectors
⇒ page 269 .
– To disconnect the high-pressure lines, counterhold the high-

pressure fitting -A- on the injectors.
Caution
Maintain cleanliness. ItGmust be ensured that no dirt gets into

. Volkswage AG
the disconnected swafuel
gen Areturn linesnor the
doesopen connections of
the injectors olk
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ho open fuel connections from dirt entrainmente ousing suit‐
r te
able
ss methods under all circumstances.
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Used injectors (piezo injectors) may be re-installed only on the

nl
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du
an
same cylinder from which they were removed.

itte
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ab
ility
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– Only loosen high pressure line on high pressure accumulator

h re
hole
-3- and high pressure pump -1-.

spec
es, in part or in w
t to the co
Note
rrectness of i
♦ Open the return line connection with a narrow screwdriver and

long-nosed pliers.
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♦ Renew clips.
nform
mercia
at
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ate
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Prote AG.

Caddy 2011 ➤
– To release fuel return line, pull clip out in direction of arrow.
– Pull fuel return line connections off injectors in

Note
♦ One clamping piece always secures two injectors and can only
be removed if both injectors are removed.
♦ Sequence for removing injectors: first remove injector for cyl‐ AG. Volkswagen AG d
inder 2, then for cylinder 1/cylinder 4, and then for cylinder 3. agen oes
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– Unscrew bolt for clamping piece. ut
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– Fit puller - T10055- with injector puller - T10402- -1-.

nl
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– Detach injector by tapping with puller - T10055- .
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ab
ility
– Repeat process at second injector.
ot p
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– Remove clamping piece with injectors.
h re
hole
spec
Installing
es, in part or in w
t to the co
If a used injector is being re-installed:
rrectness of i
– Clean injector tip and sealing surface.

l purpos
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atio
om
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Cop py
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Prote AG.

Caddy 2011 ➤
– To remove the old copper seal from the injector, carefully

clamp the copper seal in a pair of pliers so the copper seal is
just prevented from spinning. Then carefully pull and twist the
injector out of the copper seal by hand.
– Clean injector tip and sealing surface.
AG. Volkswagen AG d
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– Fit new copper sealing ring -1- on injector -2- with help of as‐
ility
ot p
sembly sleeve - T10377- . Use “narrow” side of assembly
wit
, is n
sleeve - T10377- for this.
h re
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spec
es, in part or in w
Note
t to the co
Lubricate all O-rings with engine oil or assembly oil before instal‐
ling.
rrectness of i
l purpos
– Carefully slide new O-ring over fuel return connection to avoid

damaging O-ring. nform
ercia
– Clean sealing surface of injector in cylinder head and injector

shaft.
m
at
om
ion
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or
WARNING
his
ate
do
priv
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or
Only cleaning set - VAS 6811- may be used for cleaning the
f
en
g
sealing surface of the injector bore.

n
t.
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Cop py
t.
For detailed information on how to use the cleaning set as well
rig
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as the order in which its components are applied, refer to the
cop Vo
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⇒ operating manual provided with the cleaning set - VAS
cted agen
Prote AG.
6811- .
– Renew seal -1- for injector bore using assembly sleeve -

T10377- .

Caddy 2011 ➤
– Fit clips before fitting the injector. To do this, grease lightly.

• Ensure that the injector bore is clean before fitting.
– Slide clamping piece onto injectors (piezo injectors). When
doing so, note the installation position ⇒ page 269 .
– Always carefully insert 2 injectors with clamping piece into in‐
jector bores in cylinder head.
Caution

Avoid damage to the injectors and prevent them coming into
contact with the cylinder head.
It should be possible to align the injectors while fitting the high-

pressure lines by hand.
– Tighten bolts initially to no more than 1 - 2 Nm.
After renewing an injector, the adaptation value must be written
into the engine control unit.
In addition, check for all other injector units that the values from
the “adaptation for injectors” are stored in the engine control unit.
Do not attempt to re-enter these values .ifVothe
lkswcorrect
agen AG
values are
already stored in the engine control
ks wagenunit.
AG does
n ol ot g
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The adaption procedure ed⇒ page 284 is described in ⇒ Vehicle ran
b ua
ris
diagnostic tester. tho tee
o u ra
sa c
– Install high-pressure
s lines ⇒ page 269 .
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Torque settings
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itte
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ab

ility
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is n
3.6 Adapting correction values for injectors

h re
ole,
spec
The function “Adaptation of injectors” serves to correct the injec‐

t to the co
tion rates for each cylinder of a common rail system individually

across the entire ignition map range.
The 6-digit adaptation value -1- (details in illustration are for ex‐
rrectne
ample only) are marked separately on each injector. The marked

values may consist of letters and/or numbers.
ss o
1- Adaptation value
cial p
f inform
2- Part number
mer
atio
m
After renewing an injector, the adaptation value must be written

o
n
c
into the engine control unit.

i
or
n thi
te
sd
a
After renewing the engine control unit, the “adaptation values for
iv
o
pr
the injectors” must be transferred to the new engine control unit.

um
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ng
t.
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The work procedure for the adaptation is described in ⇒ Vehicle
Co
op py
diagnostic tester. t. C rig
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Vo
In addition, check for all other injector units that the values from
co lksw
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the “adaptation for injectors” are stored in the engine control unit. Prote AG.
Do not attempt to re-enter these values if the correct values are
already stored in the engine control unit.

Caddy 2011 ➤
3.7 Replacing O-ring of fuel return lines

Removing
Proceed with extreme caution. Avoid damage to fuel return line.
– Lever old O-ring very carefully off fuel return line.
Do not work with a sharp-edged tool.
Installing
Note
Avoid any rolling movement when pushing O-rings on. The O-

rings must not be twisted in their seats in fuel return line.
n AG. Volkswagen AG
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Proceed with extreme iscaution.
ed
b Avoid damage to the O-ring and ara
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fuel return line. tho
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ss
– Clean seating surfaces for O-rings on fuel return line very
ce
le
thoroughly.
un
pt
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– Carefully push O-ring -1- onto its seat -2-.
rm
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ercia
3.8 Check pressure retention valve in fuel

m
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return line
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♦ Pressure gauge - VAS 6330-

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ng
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Cop py
t. rig
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Prote AG.
♦ Adapter - VAS 6330/3-1-

♦ Adapter - VAS 6330/3-2-
The pressure retention valve has the task of maintaining a resid‐
ual pressure (control volume) of approx. 1 bar in the return lines.
This residual pressure is required for the control function of the
piezo injectors.

Caddy 2011 ➤
WARNING
♦ Read rules for cleanliness and the instructions for working

on the fuel system ⇒ page 8 .
– Clean return line connection from first cylinder (e.g. with de‐
greaser) before removing.
– Dry return line connection of first cylinder.
– Cover return line connection of first cylinder with a clean lint-
free cloth.
– Pull return line connection off first cylinder. To do so, pull out
release clip -arrow-.
Note
♦ Open return line connection with a narrow screwdriver and

long-nosed pliers.
. Volkswagen AG
gen AG does
♦ Maintain cleanliness. No dirt must be allowed
Vol
ksw to get into the
a
not
disconnected fuel return lines or theedopen
by connections on the gu
ara
injectors (piezo injectors). thoris nte
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au ra
♦ Always renew clips. ss c
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itte
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erm
ab
ility
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spec
es, in part or in w
t to the co
– Install tester for fuel return system - 6330- with adapters -VAS
6330/3-1- and -VAS 6330/3-2- between return line connection
on injector and return line.
rrectness of i
– Start the engine.

l purpos
– Check pressure on pressure gauge.

nform
ercia
♦ Specification: approx. 1.0 bar

m
at
If the specification is not reached, replace the pressure retention

om
ion
valve.
c
in t
or
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te
After any work on the fuel system

a
do
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cum
or
• Observe instructions for working on fuel system ⇒ page 5 .

f
en
ng
t.
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Cop py
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Prote AG.

Caddy 2011 ➤
3.9 Checking return flow rate of injectors at

AG. Volkswagen AG d
starter speed Volksw
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Note s au ra
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nl
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♦ Leaky regulating valves in injectors may lead to irregular en‐
du
an
itte
gine running or may prevent engine from starting.
y li
erm
ab
ility
♦ To check regulating valves for soiling and related higher leak‐
ot p
age, in addition to the "classical" return quantity measurement,
wit
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checking with vacuum is also possible.
hole
spec
♦ Observe instructions for working on fuel system ⇒ page 5 .
es, in part or in w
t to the co
rrectness of i
– Open return line connection -3- of injectors on fuel return pipe
using a narrow blade screwdriver and long-nose pliers.
l purpos
– Collect escaping fuel with a cleaning cloth.
nform
mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
0.5 bar low pressure fuel system:

– Seal open return line connection with a blanking plug
-arrow-.

Caddy 2011 ➤
6.0 bar low pressure fuel system:

– Seal open return line connection with a blanking plug
-arrow-.
Continuation all vehicles
– Measure at turnover speed ≥ 230 rpm during engine start.
• Specification: return volume 0 ml
• Droplets are allowed
• If a flow rate can be measured, at least one of the injectors is
defective.
– Check injectors with vacuum ⇒ page 288 .
3.10 Testing injectors
Note
♦ Leaky regulating valves in injectors may lead to irregular en‐

gine running or may prevent engine from starting.
♦ To check regulating valves for soiling and related higher leak‐
age, in addition to the "classical" return quantity measurement,
checking with vacuum is also possible.
♦ Observe instructions for working on fuel system ⇒ page 5 .

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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h
aut ra
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nl
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erm
ab
ility
ot p
wit
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♦ Locally manufacture an -adapter- from a return line.

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
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ate
do
riv
p
cum
for
en
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– Collect escaping fuel with a cleaning cloth.

n
t.
yi Co
Cop py
– Open cleaned return line connection of injector to be tested
t. rig
gh ht
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using a narrow blade screwdriver and long-nosed pliers.
p by
o Vo
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cted agen
Prote AG.

Caddy 2011 ➤
Always renew clips.
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
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Pull off return line in direction of arrow.
l purpos
WARNING
nform
ercia
♦ The fuel and the fuel lines in the fuel system can become
m
at
very hot (danger of scalding)!
om
ion
c
in t
r
♦ The fuel system is also under pressure! Before opening

o
his
e
the system, place a cloth around the connection and re‐

at
do
riv
duce pressure by carefully loosening the connection!

p
cum
for
en
g
♦ Wear eye and hand protection when performing any type

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of repair work on the fuel system! C py
t. rig
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co lksw
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Prote AG.
– Undo fuel high-pressure line -2-. To do this, only undo union
nuts on high-pressure accumulator -1-.
– Connect clean, blown-out adapter to injector to be tested.
– Use hand vacuum pump - VAS 6213- to generate vacuum of

approx. -500 mbar.
If injectors are OK, pressure remains constant for 30 seconds.
If injectors are defective, the pressure drops back to 0 bar within
2 to 3 seconds.
Repeat check is necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew injectors ⇒ page 279 .

Caddy 2011 ➤
4 High-pressure pump
⇒ “4.1 Assembly overview - high-pressure pump and fuel pres‐
sure regulating valve N 276 ”, page 290
⇒ “4.2 Removing and installing high-pressure pump”, page 291
⇒ “4.3 Pressure testing high-pressure pump”, page 295 AG. Volkswagen AG d
agen oes
lksw not
4.1 Assembly overview - high-pressure pump and fuel pressure regulating Vo gu
d by ara
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valve - N 276- aut
hor eo
ra
ss c
ce
e
nl
pt
1 - High-pressure pump,
du
an
itte
0.5 bar low-pressure fuel sys‐
y li
erm
ab
tem
ility
ot p
❑ Fitted with pressurisa‐
wit
, is n
tion pump on high pres‐
h re
hole
sure pump
spec
es, in part or in w
2 - High-pressure pump,
t to the co
6.0 bar low-pressure fuel sys‐
tem
rrectness of i
❑ Without booster pump.
❑ The requisite 6.0 bar
l purpos
pressure in the low pres‐

sure fuel system is gen‐
nf
ercia
erated by the fuel deliv‐
or
ery unit.
m
m
atio
m

o
n in
or c
valve - N 276- , 0.5 bar low-
thi
te
sd
iva
o
r
rp
cu
o
m
f
Note
en
ng
t.
yi Co
Cop py
♦ The fuel pressure regulating
t. rig
gh ht
yri by
valve - N 276- of the 0.5 bar low- op Vo
by c lksw
pressure fuel system looks the cted agen
Prote AG.
same as that of the 6.0 bar low-
pressure fuel system.
♦ Refer to the part number index in
⇒ Electronic parts catalogue
(ETKA) .

valve - N 276- , 6.0 bar low-
Note
♦ The fuel pressure regulating

valve - N 276- of the 6.0 bar low-
pressure fuel system looks the
same as that of the 0.5 bar low-
pressure fuel system.
♦ Refer to the part number index in
⇒ Electronic parts catalogue
(ETKA) .

Caddy 2011 ➤
4.2 Removing and installing high-pressure pump

equipment required
♦ Tapered roller bearing pull‐
er - T40064-
♦ Press tool - T40064/1-
50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss 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
♦ Pliers - 3314-
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.
4. High-pressure pump 291

Caddy 2011 ➤
Removing
Caution
♦ Observe rules for cleanliness and the instructions for

working on the fuel system ⇒ page 8 .
Risk of irreparable damage to high-pressure pump if allowed
to run dry.
♦ The high-pressure pump must first be filled with fuel before
the engine is started. The high-pressure pump must not
be allowed to run while still empty. Initial fuel filling
⇒ page 257 .
♦ Protect open fuel connections from dirt entrainment using
suitable methods under all circumstances.
– Remove toothed belt from camshaft and high-pressure pump

⇒ page 121 .
Caution

AG. Volkswagen AG d
agen oes
olksw not
yV gu
– Position pliersise-d3314- with groove -arrow A- on support
b ara sleeve
nte
r
shoulder -arrow
ut
ho B-. eo
ra
s a c
s
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
– Carefully pull connectors off glow plugs in

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

Caddy 2011 ➤
– Detach connector -1- of fuel temperature sender - G81- .
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
ility
ot p
– Unscrew securing bolt -arrows-. Lay coolant return line to side.
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
co lksw
by
cted agen
Prote AG.
– Pull fuel supply line -arrow- off high-pressure pump.

Caddy 2011 ➤ . Volkswagen AG
4-cylinder diesel engine gen AG
wa(1.6 l engine, commondoes rail) - Edition 09.2016
olks no
V t gu
by ara
ed nte
– Unscrew bolts -1-, tho-3- and -4-. Detach connector -arrow- of fuel e o
ris
metering valves a- N290- .
u ra
c
s
ce
e
– Pull off fuel return line -2-.
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
– Unscrew bolts -4- and then remove bracket.
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
– Remove high-pressure fuel line between high-pressure pump
Prote AG.
and high-pressure accumulator ⇒ Item 12 (page 256) .

– Remove toothed belt pulley from high-pressure pump.
– Hold hub of high-pressure pump with the counterhold -

T10051- and undo the nut -1-.

Caddy 2011 ➤
– Position puller - T40064- with thrust piece - T40064/1- and pin

- T40064/2- as shown and pull hub off high-pressure pump. If
necessary, use an open-ended spanner, width across flats 24
mm, for counterholding.
– Unscrew bolts -arrows- of high-pressure pump.

– Remove high-pressure pump.
Installing
olkswagen AG
en AG. V
Install in reverse order,
olks noting the following:
wag does
not
V gu
d by ara
After any work
or
iseon the fuel system nte
h eo
ut r
• Observe
ss
a instructions for working on fuel system ⇒ page a5c .
ce
e
nl
– Read event memory and, if necessary, delete event memory pt

du
an
entry ⇒ Vehicle diagnostic tester.
itte
y li
erm
ab
– Filling/bleeding high-pressure pump/fuel system ⇒ page 257 .
ility
ot p
wit
, is n
Torque settings
h re
hole
spec

es, in part or in w
t to the co
Specified torques -1, 3, 4-

rrectness of i

l purpos
1 8 Nm.
nf
ercia
2 8 Nm.
orm
3 20 Nm.
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
yri
4.3 Pressure testing high-pressure pump
p by
o Vo
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Make an -adapter- from a high-pressure line.
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
y li
rm
ab
pe
ility
ot
wit
♦ During further work, this carefully cleaned adapter is to be
, is n
h re
connected to the high-pressure connection on the high-pres‐
hole
spec
sure pump, free of tension.
es, in part or in w
t to the co
• Tests on fuel low-pressure side have been performed and
were not cause for complaint.
• Fuel tank is filled with clean fuel.
rrectness of i
• Starter motor turns at starting speed ≥ 230 rpm ⇒ Electrical
l purpos
system; Rep. gr. 27

• Observe safety precautions ⇒ page 1 .
nform
ercia
• Comply with rules for cleanliness ⇒ page 8

m
a
com
tion in
• Observe instructions for working on fuel system ⇒ page 5
r
te o
thi
s
iva
do
r
rp
cum
– Remove high-pressure fuel line -2- between high-pressure
fo
en
g
pump and high-pressure accumulator ⇒ Item 12 (page 256) .

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

Caddy 2011 ➤
– Connect thoroughly clean, locally made adapter to high-pres‐

sure connection of high-pressure pump.
– Connect hand vacuum pump - VAS 6213- to custom-made
adapter.
– Use hand vacuum pump - VAS 6213- to generate at least 1
bar pressure.
If high-pressure pump is OK, pressure should stay constant for
more than 30 seconds.
If high-pressure pump is defective, the pressure drops back to 0
bar within 2 to 3 seconds.
Repeat check is necessary, observe pressure loss at hand-oper‐
ated vacuum pump - VAS 6213- .
– Renew high-pressure pump ⇒ page 291 .
AG. Volkswagen AG d
Torque settings lksw
agen oes
not
o
yV gu
♦ ⇒ “1.3 Assembly overview - fuel system”, pagerised 254
b ara
nte
ho eo
ut ra
Component Torque
ss a setting c
ce
le
Adapter 20 Nm.
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
5 Intake manifold
AG. Volkswagen AG d
⇒ “5.1 Assembly overview - intake manifold”, page 298 agen oes
olksw not
byV gu
ara
d
⇒ “5.2 Removing and installing intake manifold”, page oris 299
e nte
h eo
ut ra
⇒ “5.3 Removing and installing throttle valve module
ss a J338 with c
throttle valve potentiometer G69 ”, page 302
ce
e
nl
pt
du
an
5.1 Assembly overview - intake manifold
itte
y li
erm
ab
ility
ot p
wit
1 - Guide tube , is n
h re
hole
❑ For oil dipstick.
spec
es, in part or in w
2 - Sealing ring
t to the co
3 - Gasket
rrectness of i
l purpos
4 - Bolt
❑ 8 Nm.
nf
ercia
orm
m
atio
om
n in
c
6 - Coolant line
or
thi
te
sd
a
7 - Bolt
iv
o
r
rp
cu
❑ 9 Nm.
o
m
f
en
ng
t.
yi Co
8 - Bolt . Cop py
rig
ht
❑ 9 Nm. rig ht
py by
co Vo
by lksw
9 - Intake manifold cted agen
Prote AG.
⇒ page 299
10 - Bolt
❑ 9 Nm.
11 - Holder
❑ For exhaust gas recircu‐
lation cooler change‐
over valve - N345- .
12 - Bolt
❑ 9 Nm.
cooler changeover valve -
N345-
14 - Gasket
15 - Connecting pipe
❑ To exhaust gas recirculation cooler.
16 - Bolt
❑ 20 Nm.
17 - Clip
❑ 5 Nm.
18 - Connection
❑ For exhaust gas recirculation

Caddy 2011 ➤
19 - Bolt
❑ 8 Nm.
20 - Sealing ring
21 - Throttle valve control module - J338- with throttle valve potentiometer - G69-
22 - Bolt
AG. Volkswagen AG d
❑ 8 Nm. agen oes
olksw not
y V gu
b ara
23 - Bolt rise
d
nte
ho eo
❑ 9 Nm. s aut ra
c
s
24 - Fastener
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
5.2 Removing and installing intake manifold
wit
is n
h re
ole,
spec
♦ Pliers - 3314-
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
co lksw
by
cted agen
Prote AG.
5. Intake manifold 299

Caddy 2011 ➤
Removing
WARNING

– Open cable guide catch -arrows- to lay wiring harness to side.
Caution

3314- too firmly to separate the connectors, otherwise the

shoulder -arrow B- and pull connectors off glow plugs.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut 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
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Unclip vacuum lines -1- and -2-.

– Pull catch to one side -arrow- and pull off exhaust gas recir‐
culation cooler changeover valve - N345- -3- downwards and
place to one side.
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
y li
rm
ab
– Unscrew bolts -arrows- and place coolant return line to one
pe
ility
ot
side
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
ti
on in
r
te o
thi
Removing high-pressure accumulator ⇒ page 275 .
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.
– Pull off connector -2- from throttle valve module - J338- with
throttle valve potentiometer - G69- .
– Remove bolt -3- from dipstick connection.

Caddy 2011 ➤
– Remove charge air hose -2- between throttle valve module -

J338- with throttle valve potentiometer - G69- and charge air
pipe.
– Remove exhaust gas recirculation connecting pipe. Open clip

-1-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
– Unscrew bolts -arrows- for intake manifold diagonally from
, is n
h re
outside to inside using socket T30 - T10405- .
hole
– Carefully remove intake manifold. spec

es, in part or in w
t to the co
Installing
rrectness of i
– Renew seals and gaskets.

l purpos
– First, insert bolts into holes in intake manifold.

nform
ercia
– Carefully guide intake manifold together with seals and secur‐

ing bolts to fitting location.
m
a
com
tio
– Tighten intake manifold bolts alternately in diagonal sequence

n in
r
working from the outside to the inside.

te o
thi
s
iva
do
Install high-pressure accumulator .

r
rp
cum
fo
en
g
Torque settings
n
t.
yi Co
op py
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 298
t. C rig
gh ht
pyri by
Vo
o
c by lksw
cted agen
Prote AG.
5.3 Removing and installing throttle valve

module - J338- with throttle valve poten‐
tiometer - G69-

Caddy 2011 ➤
AG. Volcommon
kswagen rail) - Edition 09.2016
n AG do
wage es n
olks ot g
♦ Torque wrench - V.A.G 1410- ed
by
V ua
ran
oris tee
th or
au ac
ss
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
Removing
l purpos

nform
ercia

m
a
– Loosen hose clamps -1- and -2- and remove air hose.
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.

– Disconnect electrical connector -1- on charge pressure sender
- G31- and remove air pipe.

Caddy 2011 ➤
– Disconnect connector -2-.

– Remove bolt -1- for dipstick guide tube.
– Unscrew bolts -arrows- and remove throttle valve module -
J338- with throttle valve potentiometer - G69- .
Installing
Torque settings
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 298
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
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
co lksw
by
cted agen
304
Prote AG.
Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
6 Air filter
AG. Volkswagen AG d
agen
⇒ “6.1 Assembly overview - air filter housing”, page 305 Volksw
oes
not
gu
d by ara
⇒ “6.2 Removing and installing air filter housing”, pageor306
ise nte
eo
h
ut ra
6.1 Assembly overview - air filter housing s a c
s
ce
le
un
pt
an
d
itte
y li
1 - Hose connection
rm
ab
pe
ility
2 - Air intake hose
ot
wit
, is n
h re
❑ To turbocharger.
hole
spec
❑ Check for soiling and
leaves. es, in part or in w
t to the co
3 - Bolt
❑ 1.5 Nm.
rrectness of i
4 - Air mass meter - G70-
l purpos

⇒ page 310
nform
ercia
5 - O-ring
m
a
com
t
ion in
r
❑ Install with silicone-free

te o
thi
lubricant
s
iva
do
r
rp
cum
6 - Bolt
fo
en
ng
t.
yi
❑ 1.5 Nm.
Co
Cop py
t. rig
gh
7 - Bolt
ht
pyri by
Vo
o
by c lksw
❑ 8 Nm. Prote
cted AG.
agen
8 - Sleeve
9 - Washer
10 - Air filter upper part
❑ With flow rectifier de‐
pending on equipment
❑ Remove dirt, leaves and
salt residues
11 - Air filter element
❑ Always use Genuine
Part for air filter element
❑ Observe change inter‐
vals ⇒ Maintenance ; Booklet 39
12 - Air filter lower part
❑ Remove dirt, leaves and salt residues
❑ For cold countries, an air filter lower part is installed with a hose for hot air intake.
❑ Country-specific version: With snow screen.
13 - Connection for water drain hose
❑ Cleaning
14 - Water drain hose
❑ Cleaning
15 - Flutter valve
❑ Cleaning and reinstalling.
6. Air filter 305

lkswage es n
o ot g
byV ua
d ran
ir se
Caddy 2011 ➤ tho tee
or
u
ss common rail) - Edition 09.2016
a ac
ce
e
nl
pt
du
16 - Intake air guide
an
itte
y li
❑ To lock carrier.
erm
ab
ility
ot p
❑ Remove dirt, leaves and salt residues
wit
, is n
h re
17 - Spring-type clip
hole
spec
18 - Connection hose
es, in part or in w
t to the co
❑ To turbocharger.
rrectness of i
6.2 Removing and installing air filter hous‐
l purpos
ing
nform
ercia
Removing
m
at
om
io
-arrows-.
n
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 ➤
en AG. Vcommon
olkswagen rail)
AG - Edition 09.2016
ag does
ksw not
Vol gu
– Detach connector from air mass meter - G70- -1-eand d b pull off
y ara
nte
vacuum line -2-. thoris eo
au ra
– Loosen threaded connection at air filter housing
ss -3-. c
ce
le
un
pt
– Open clip -4- and pull off hose leading to turbocharger.
an
d
itte
y li
rm
– Remove entire air filter housing.
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Remove water drain hose -arrow- from lower part of air filter.
Remove dirt and leaves from the connection and the hose.
l purpos
Remove suction hose
nform
mercia
Note
a
com
tion in
r
As it is difficult to gain access to clip on suction hose, it is better

te o
thi
to remove intake connecting pipe from turbocharger.
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
– Remove crankcase breather hose -1-.
lksw
cted agen
Prote AG.
– Pull vacuum hoses -arrows- off suction hose -3-, remove and
lay to one side. Unclip bracket.
– Completely unscrew bolt -2- (make sure bolt is captive).
– Swing intake union to the right and remove with suction hose
-3-.
Install suction hose

bocharger. -arrow-.
Installing
Install in reverse order of removal. During this step, observe the
following:
Note
♦ Use a silicone-free lubricant to install the air hose.
Torque settings
6. Air filter 307

Caddy 2011 ➤
7 Lambda probe
⇒ “7.1 Removing and installing Lambda probe G39 ”, page
olks
wag308
e es n
ot g
yV ua
db
7.1 Removing and installing Lambda probe
e ran
ris tee
tho or
- G39- ss
au ac
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
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.
Removing
– Disconnect electrical connector -arrow- for Lambda probe -
G39- .

Caddy 2011 ➤
– Unscrew Lambda probe - G39- -3-, using tool from Lambda

probe open ring spanner set - 3337- .
Installing
Note agen
AG. Volkswagen AG d
oes
olksw not
V gu
by ara
Threads of new Lambda probes are already coated with as‐
d
♦ orise nte
sembly paste; theautpaste must not get into the slots on the probe e or a
h
body. ss c
ce
le
un
pt
♦ In the case of a used Lambda probe grease only the thread
an
d
itte
with high-temperature paste - G 052 112 A3- . The high-tem‐
y li
erm
ab
perature paste must not get into the slots on the probe body.
ility
ot p
♦ When installing, the Lambda probe's electrical wiring connec‐
wit
is n
h re
tion must always be re-attached in the same locations to
ole,
prevent the Lambda probe cable from coming into contact with
spec
the exhaust pipe.
t to the co
Torque settings
rrectne
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 341
ss 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.
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Cop py
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Vo
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by c lksw
cted agen
Prote AG.
7. Lambda probe 309

Caddy 2011 ➤
8 Senders and sensors

⇒ “8.1 Removing and installing air mass meter G70 ”, page 310
⇒ “8.2 Removing and installing exhaust gas pressure sensor 1
G450 ”, page 311
⇒ “8.3 Removing and installing fuel pressure regulating valve
N276 ”, page 311
⇒ “8.4 Checking fuel pressure regulating valve N276 ”,
page 314
⇒ “8.5 Removing and installing fuel pressure sender G247 ”, page
316
⇒ “8.6 Checking fuel pressure sender G 247 ”, page 319
⇒ “8.7 Checking fuel metering valve N 290 ”, page 320
8.1 Removing and installing air mass meter

- G70-
Removing
– Carefully pull air mass meter - G70- out of guide on air filter
housing.
Installing
To ensure the proper function of the aair
genmass
AG. Volmeter
kswagen- A
G70-
G do it is
important to adhere to the following
Volkswwork sequences. es n
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Note au ac
ss
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nl
pt
du
♦ If the air filter element is very dirty or wet, particles of dirt or

an
itte
water may reach the air mass meter and falsify the measured
y li
erm
ab
air mass value. This would lead to loss of power, since a

ility
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smaller injection quantity is calculated.

wit
, is n
h re
♦ Always use Genuine part for air filter element.

hole
spec
♦ Always renew seal if damaged (infiltrating air).

es, in part or in w
t to the co
♦ Use a silicone-free lubricant to install the air hose and seal.

rrectness of i

l purpos

nform
ercia
– Check for salt residue, dirt and leaves in air mass meter and
m
at
om
air hose (clean air side).

ion
c
in t
or
– Check intake port for dirt as far as the air filter element. If con‐
his
te
tamination is found, remove salt residues, dirt and leaves from

a
do
riv
top and bottom part of air filter housing by rinsing out or using
p
cum
or
a vacuum cleaner if necessary.

f
en
ng
t.
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op
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Torque settings co Vo
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AG.

AG. Volkswagen AG d
agen Caddy
oes 2011 ➤
olksw not
yV gu
4-cylinder diesel engine (1.6 ed l engine, common rail) - Edition 09.2016
b ara
nte
ris
ho eo
ut ra
8.2 Removing and installing exhaust gas s a c
s
ce
e
pressure sensor 1 - G450-
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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nf
ercia
orm
m
atio
om
n in
or c
The exhaust gas pressure sensor 1 - G450- determines the load‐
thi
te
sd
ing of the particulate filter.
iva
o
r
rp
cu
Removing
o
m
f
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ng
t.
yi Co
– Before removing, spray solvent on hoses of exhaust gas pres‐ Cop py
. rig
sure sensor 1 - G450- .
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rig by
copy Vo
– Disconnect electrical connector -2- from exhaust gas pressure
by lksw
cted agen
Prote
sensor 1 - G450- .
AG.
– Remove screw -4-.

– Carefully pull hoses off connecting pieces in a straight line.
The two connections can easily break off the exhaust gas
pressure sensor 1 - G450- .
– Unscrew bolt -3-, and remove exhaust gas pressure sensor 1
- G450- .
Installing
Note
♦ Before installing, blow out control line for exhaust gas pressure
sensor 1 - G450- towards particulate filter with compressed air
(hoses can become obstructed or may ice up due to conden‐
sation).
♦ Make sure that hoses are securely fitted and seal properly.
♦ If the pressure line on the particulate filter was loosened, tight‐
en pressure line.
Carry out adaptation after renewing exhaust gas pressure sensor

1 - G450- and/or particulate filter ⇒ Vehicle diagnostic tester.
Torque settings
tion”, page 341
8.3 Removing and installing fuel pressure

regulating valve - N276-
8. Senders and sensors 311

Caddy 2011 ➤
♦ Open end spanner insert, AF 36 mm - V.A.G 1332/8-
♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
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un
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an
d
itte
y li
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ab
ility
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wit
is n
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ole,
spec
t to the co
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.
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Cop py
t. rig
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pyri by
Vo
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312
c by lksw
cted agen
Rep. gr.23 - Mixture preparation - injection Prote AG.
Caddy 2011 ➤
Fuel pressure regulating valve - N276- -arrow- is located in the

high pressure accumulator. It maintains constant pressure in the
high pressure accumulator and injection lines (fuel high pressure
circuit).
If the pressure in the high-pressure fuel circuit is too high, the
regulating valve opens to allow some of the fuel to flow back from
the high-pressure accumulator to the fuel tank via a return line.
If the pressure in the high-pressure fuel circuit is too low, the fuel
pressure regulating valve - N276- closes and seals off the high-
pressure section of the system from the low-pressure section.
Removing
WARNING
♦ Observe rules for cleanliness and the instructions for

working on the fuel system ⇒ page 8 .
wage es n
– Removing high-pressure accumulator ⇒ page
yV
ol275
ks . ot g
d b ua
e ran
– Clean threaded area around fuel pressure
horis regulating valve - tee
N276- (e.g. with commercially available
aut
cleaning solution) or
ac
before removing. ss
ce
le
un
pt
Under no circumstances may dirt enter the hole of the fuel rail.
an
d
itte
y li
erm
ab
ility
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Note
wit
is n
h re
ole,
Do not allow any cleaning agent to get into the connector, clean
spec
it carefully.
t to the co
– Dry fuel pressure regulating valve - N276- .
rrectne
– Loosen and unscrew fuel pressure regulating valve - N276- .
– Extract dirt from inside of fuel rail (threads and sealing sur‐ ss
face). Do not use tools or other instruments for this purpose.
o
cial p
f in
– Seal hole in fuel rail with a clean plug.

form
mer
atio
Installing
om
n
c
i
or

thi
te
sd
iva
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pr
cum
WARNING
r
fo
en
ng
t.
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op
If the fuel pressure regulating valve - N276- has been renewed,
C py
t. rig
gh
the learnt values for the fuel system must be reset ⇒ Vehicle
ht
pyri by
Vo
diagnostic tester.
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Note
♦ The fuel pressure regulating valve - N 276- cannot be re-used.

♦ Make sure that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are un‐
damaged.
♦ Check sealing surface hole.
♦ Lubricate thread and deformable sealing lip of fuel pressure
regulating valve - N276- with Molybdenum grease.
– Tighten fuel pressure regulating valve - N 276- by hand.

– Align new fuel pressure regulating valve so that connecting
line is free of tension after connector is attached.
– Tighten using torque wrench (40 to 200 Nm) - V.A.G 1332-
with open end spanner insert, AF 36 mm - V.A.G 1332/8- .
– Install high-pressure accumulator ⇒ page 275 .
– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
– Read event memory.
– Then test drive the vehicle, accelerating to full throttle at least
once. G. Volkswage nA n AG d
wage oes
– Then check high-pressure section of fuel system Vol again for
ks not
gu
by
leakage. ise
d ara
nte
r
ho eo
– Read event memory again. aut ra
ss c
ce
Torque settings
e
nl
pt
du
an
itte

y li
erm
ab
ility
ot p
8.4 Checking fuel pressure regulating valve

wit
, is n
h re
- N276-
hole
spec
es, in part or in w

t to the co
♦ Measuring glass - V.A.G 1602/1-

rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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t.
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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 ➤
♦ Measuring container, fuel-resistant
WARNING

• Engine at operating temperature.

AG. Volkswagen A
gen G do
swa es n
• Air conditioner
by
Vol switched off
k ot g
ua
ed ran
ris tee
tho or
au ac
ss Note
ce
e
nl
pt
du
♦ A fuel pressure regulating valve - N 276- leaking during start‐

an
itte
y li
ing will result in an increased return flow rate.

erm
ab
ility
ot p
♦ The fuel high-pressure required for starting will not be ach‐

wit
, is n
ieved.
h re
hole
spec
es, in part or in w
t to the co
– Remove noise insulation from injectors.

– Remove fuel return hose from high pressure accumulator, re‐
rrectness of i
leasing hose clip -arrow- to do so.

l purpos
– Seal open fuel return hose using a bung from engine bung set
- VAS 6122- .
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 ➤
– Connect auxiliary hose -2- to return connection of high pres‐

sure accumulator -3-.
– Hold auxiliary hose in measuring container -4- to measure re‐
turn quantity.
1) Check with engine running agen
AG. Volkswagen AG d
oes
olksw not
– Start engine and run at idling speed for 30 seconds.
ed byV gu
ara
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• Specified amount in 30 seconds: ≥75 ml auth o eo
ra
ss c
If the specification is not attained, the fuel pressure regulating
ce
e
nl
valve - N 276- is defective.
pt
du
an
itte
y li
2) Check with engine running
erm
ab
ility
ot p
If condition specified under 1) is met, increase engine speed to ≥
wit
, is n
2000 rpm.
h re
hole
spec
es, in part or in w
t to the co
• If the specification is not attained, the fuel pressure regulating
rrectness of i
3) Engine cannot be started.
l purpos
Carry out check at starter speed.
nf
ercia
o
rm
m
atio
m

o
n in
or c
• If the specification is not attained, the fuel pressure regulating
thi
te
sd
a

iv
o
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rp
cu
o
m
f
en
ng
8.5 Removing and installing fuel pressure

t.
yi Co
op py
sender - G247-
. C rig
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rig by
copy Vo
by lksw
Special tools and workshop equipment required Prote
cted AG.
agen

Caddy 2011 ➤
♦ The fuel pressure sender - G247- -2-is located in the high-

pressure accumulator. It measures the current fuel pressure
in the high-pressure system and sends a voltage signal to the
engine control unit - J623- .
The fuel pressure sender - G247- is located in the fuel rail, meas‐
ures the current fuel pressure in the high-pressure system and
transmits a voltage signal to the diesel direct injection system
control unit - J248- .
If the sender fails, the pressure is regulated by the engine control
unit using a map. In limp home mode, the maximum engine speed
is limited to approx. 3000 rpm.
Removing
Caution
Read through the rules for cleanliness and the instructions for
G. Volkswagen AG d
working on the fuel system ⇒ page 8 . lkswagen A oes
n o ot g
yV
Follow these instructions before starting work and while work‐
b ua
ed ran
ris
ing on the fuel system. utho tee
or
a ac
ss
ce
le
un
pt
– Clean threaded area around fuel pressure sender (e.g. with

an
d
itte
cold cleaning solvent) before removing. Always ensure that no

y li
rm
ab
dirt enters the hole in the high pressure accumulator.

pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
Do not allow any cleaning agent to get into the connector, clean
it carefully.
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 ➤
– Dry fuel pressure sender - G247- -2-.

– Pull electrical connector -1- off fuel pressure sender - G247-
-2-.
– Unscrew fuel pressure sender - G247- -2-.
– Use suction device to extract dirt from high-pressure accumu‐
lator hole (threads and sealing surface). Do not use tools or
other instruments for this purpose.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
Seal the high-pressure accumulator hole immediately. The in‐ ir se
d b ua
ran
gress of dirt must be prevented with a suitable sealing plug.tho tee
or
au ac
ss
Installing
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
♦ Fuel pressure sender - G247- has a deformable sealing lip,
es, in part or in w
not a seal, for sealing purposes.
t to the co
♦ Check that sealing surfaces (deformable sealing lip) and
threads on fuel pressure sender - G247- are undamaged. Re‐
rrectness of i
using fuel pressure sender - G247- if possible if it has been
tested OK.
l purpos
♦ Also check sealing surface in hole of high pressure accumu‐

lator.
nform
ercia
♦ Start of thread and deformable sealing lip of fuel pressure reg‐

m
a
com
ti
ulating valve - N276- must be moistened with diesel.
on in
r
te o
thi
s
– Tighten fuel pressure sender - G247- by hand.
iva
do
r
rp
cum
fo
– Tighten fuel pressure sender - G247- to specified torque.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
Note yri
p by
co Vo
by lksw
cted agen
Prote
The high-pressure connections must “not” be opened for bleed‐
AG.
ing; fuel system bleeds itself automatically.
– Filling/bleeding high-pressure pump/fuel system ⇒ page 257 .

– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
– Read event memory again. Clear faults, if necessary.
– Renew the affected component if leakage still occurs after
tightening to the correct torque.
– Then test drive the vehicle, accelerating to full throttle at least
once. Check high pressure part of fuel system again for leaks.

Caddy 2011 ➤
Note
emergency running mode during road test. Switch off engine and
delete event memory. Then continue with a road test.
– Read event memory again.

Torque settings
8.6 Checking fuel pressure sender - G 247-
WARNING

olkswagen AG
en AG. V
Vol
ksw
ag does
not
before starting work and while working on the fuel
ed
b system.
y gu
ara
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
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wit
, is n
♦ Fuel pressure sender - G 247- -2- is located in fuel rail. It
h re
measures the current fuel pressure in the high-pressure sys‐
hole
spec
tem and transmits a voltage signal to the engine control unit -
es, in part or in w
J623- .
t to the co
♦ If engine cannot be started though it can be with the connector
removed, fuel pressure sender - G 247- is defective.
rrectness of i
♦ With connector removed, a substitute value is taken from con‐
l purpos
trol unit for starting. If engine start is not possible with con‐
nector removed, the problem is not on fuel pressure sender -
G 247- .
nform
ercia
♦ In the event of sender failure, pressure regulation is controlled

m
at
om
using a map from the engine control unit. ion

c
in t
or
♦ In limp home mode, the maximum engine speed is limited to

his
ate
approx. 3000 rpm.

do
priv
cum
for
en
ng
t.
yi Co
– Disconnect electrical connector -1- at fuel pressure sender - t. Cop py
G 247- -2-.
rig
gh ht
pyri by
Vo
o
by c
– Perform check as described.
lksw
cted agen
Prote AG.
♦ Carry out electrical tests for fuel pressure sender - G 247- us‐
ing ⇒ Vehicle diagnostic tester.

Caddy 2011 ➤
8.7 Checking fuel metering valve - N 290-

– With engine running, remove connector from fuel metering
valve - N 290- -2-.
Note
Valve is closed without power.
♦ If engine stalls: fuel metering valve - N290- OK.

♦ If engine continues running: renew high-pressure pump
⇒ page 291 .
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
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.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
9 Engine (motor) control unit

⇒ “9.1 Removing and installing engine (motor) control unit J623
”, page 321
⇒ “9.2 Removing and installing anti-theft engine control unit J623
”, page 322
9.1 Removing and installing engine (motor)

control unit - J623-
If the engine control unit is to be replaced, connect ⇒ Vehicle di‐
agnostic tester and carry out “Renew control unit”.
Removing
– Remove plenum chamber bulkhead ⇒ General body repairs;
– Completely unscrew bolts -arrows- of control unit cover.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c
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nl
pt
du
an
itte
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erm
ab
ility
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– Undo nuts -arrows- of control unit bracket.

wit
, is n
h re
hole
– Release connector from engine control unit and pull off.

spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
r
– Press catches -1- and -2- outwards. Then pull engine control
o
his
e
unit off control unit bracket in -direction of arrow-.

at
do
priv
cum
or
Installing
f
en
ng
t.
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Install in reverse order, noting the following: . Cop py
rig
ht ht
rig
– Push engine control unit onto control unit bracket until it en‐
py by
co Vo
gages in catches.
by lksw
cted agen
Prote AG.
– Attach and lock connectors.
9. Engine (motor) control unit 321

Caddy 2011 ➤
– Tighten nut -arrows-.
– Tighten bolts -arrows-.

– Check previous coding and adapt new control unit ⇒ Vehicle
diagnostic tester.
– Read event memory of new engine control unit and clear if
necessary ⇒ Vehicle diagnostic tester.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Carry out road test.
– Again read control unit event memory. AG. Volkswagen AG d
agen oes
ksw
Torque setting by
Vol not
gu
d ara
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Component Torque ut setting
ho eo
ra
s a c
Nut s10 Nm.
ce
e
nl
pt
Bolt 5 Nm.
du
an
itte
y li
erm
ab
ility
9.2 Removing and installing anti-theft en‐
ot p
wit
, is n
gine control unit - J623-
h re
hole
spec
es, in part or in w
t to the co
Removing rrectness of i
If the engine control unit is to be replaced, connect ⇒ Vehicle di‐

l purpos
agnostic tester and carry out “Renew control unit”.

nf
ercia
or
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐

m
m
atio
screen wiper system; Removing and installing wiper arms .

om
n in
or c
– Remove plenum chamber bulkhead ⇒ General body repairs;

thi
e

t
sd
iva
o
r
rp
cu
– Push down retaining frame in direction of -arrow- and remove

o
m
f
en
ng
engine control unit.

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Unscrew shear-head bolts -arrows- using a pair of pliers.
n AG. Volkswagen AG
– Insert screwdriverolbetween
ksw
age both locking plates
does -arrow-.
no
V t gu
by a
– Carefully press
ris
ed screwdriver in -direction of arrow- and
ran bend
tee
retainingutbar
ho -1- upwards at the same time. or
a
a c
ss
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
– Bend retaining bar -1- in -direction of arrow- until it can be t to the co

pulled off connector.
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
t. rig
– Push locking devices of connectors in -direction of arrow- and
gh ht
pyri by
pull off connectors.
co Vo
by lksw
cted agen
Prote AG.
Installing
9. Engine (motor) control unit 323

Caddy 2011 ➤
en AG. V
olkswagen AG
ag does
ksw not
Vol gu
– Fit connectors to engine control unit and push locking devices ed b y ara
nte
to stop in -direction of arrow-. ho
ris eo
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
– Fit retaining bar -1- onto connectors and press it in direction
of -arrow-. l purpos
– Guide pin -2- to stop into hole on valve timing housing.
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
– Use new shear-head bolts to secure retaining bar to engine by c lksw
cted agen
control unit -arrows-.
Prote AG.
– Tighten shear-head bolts -arrows- uniformly until bolt heads

shear off.
– Place engine control unit into retaining frame and push up‐
wards in direction of -arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Install wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .

Caddy 2011 ➤
26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 325
⇒ “1.2 Separating exhaust pipes, silencers”, page 326 . Volkswagen AG
gen AG does
swa
⇒ “1.3 Aligning exhaust system free of stress”, page 327 yV
olk not
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d b ara
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⇒ “1.4 Installation position of clamp”, page 328 horis
eo
aut ra
1.1 Assembly overview - silencers ss c
ce
e
nl
pt
du
an
itte
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erm
ab
Note
ility
ot p
wit
, is n
h re
hole
spec
bodywork. If necessary, loosen double clamp and align si‐
es, in part or in w
lencer and exhaust pipe so that sufficient clearance is main‐
t to the co
tained to the bodywork and the support rings are evenly
loaded.
rrectness of i
♦ Renew self-locking nuts.
l purpos
1 - Clamping sleeve
nform
ercia
❑ Before tightening, align

m
at
cold exhaust system
om
ion
free of tension
c
in t
or
his
e
❑ Installation position
at
do
riv
⇒ page 328
p
cum
or
❑ Tighten bolted connec‐

f
en
ng
t.
yi
tions evenly.
Co
Cop py
ht. rig
❑ 25 Nm. opy
rig by
Vo
ht
c lksw
2 - Front silencer
by
cted agen
Prote AG.
3 - Retaining ring for front si‐

lencer
4 - Holder
❑ Observe installation po‐
sition
5 - Bolt
❑ 25 Nm.
6 - Mounting
❑ With retaining ring
7 - Rear silencer
8 - Coupling point
❑ Marked by impressions
on exhaust pipe.
❑ During production, front
and rear silencers are
installed as a single
component. For repairs,
front and rear silencers
are supplied separately.
1. Exhaust pipes, silencers 325

Caddy 2011 ➤
❑ The connection is made with a clamp.
❑ Installation position of rear clamp ⇒ page 328
❑ Evenly tighten threaded connections of clamping sleeve
❑ Cutting exhaust pipe ⇒ page 326 .
9 - Holder
❑ Observe installation position
10 - Retaining ring for rear silencer
11 - Tunnel cross-piece
1.2 Separating exhaust pipes, silencers

♦ Chain-type pipe cutter - VAS 6254-
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
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
♦ or body saw - VAS 6780-

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
co lksw
by
cted agen
Prote AG.
326 Rep. gr.26 - Exhaust system

olkswagen AG Caddy 2011 ➤
en AG. V
4-cylinder diesel
olkswagengine (1.6 l engine,
doescommon rail) - Edition 09.2016
no
yV t gu
db ara
Sequence of operations ir se nte
ho eo
aut ra
– Cut through exhaust pipe at separating point atssright angles c
ce
e
-arrow A- using chain pipe cutter - VAS 6254- or body saw -
nl
pt
du
VAS 6780- .
an
itte
y li
erm
ab
– When installing, fit repair double clamp at side markings
ility
ot p
-arrows B-.
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
e
1.3 Aligning exhaust system free of stress

t
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
op
• The exhaust system must be aligned when cold. C py
t. rig
gh ht
yri by
– Loosen threaded connection -3- and -4-. cop Vo
by lksw
cted agen
Prote
– Align clamp -1- with marking -A- on front exhaust pipe -2-
AG.
(-arrow- points in direction of travel).

• Dimension -a- = 5 mm
• The bolts must be on the right and the ends of the bolts must
not protrude beyond the lower edge of the clamp.
– Push rear silencer -2- forwards into clamp until dimension

-a- of 15…17 mm is attained on bracket -1- between mount‐
ings for body and rear silencer.
– Align rear silencer -2- horizontally.
– Tighten double clamp bolts in this position.
– Once bolts have been tightened, check distance -a- and cor‐
rect if necessary.
Torque settings
♦ ⇒ “1.1 Assembly overview - silencers”, page 325
1. Exhaust pipes, silencers 327

Caddy 2011 ➤
1.4 Installation position of clamp
Note
Gradual introduction of clamp with continuous clip.
Specified torque and mounting dimensions of clamping sleeve.

Clamp -A- with 2 individual clips.
Tightening torque 25 Nm
Clamp -B- with continuous clip.
Tightening torque 35 Nm
Installation dimension -a- for vehicles with marking on front ex‐

haust pipe
1 - Clamping sleeve
2 - Front exhaust pipe
a - Installation dimension -a- = 5 mm
A - Marking AG. Volkswagen AG d
agen oes
olksw not
y V gu
Installation dimension (for front clamping sleeve only) d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
y li
Installation position of clamp
erm
ab
ility
ot p
– Install clamp so that end of bolt -arrow- does not extend be‐
wit
is n
yond lower edge of clamp. h re

ole,
• The threaded connection of the front clamp faces to the right.

spec
t to the co
• The threaded connection of the rear clamp faces to the rear.

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
co lksw
by
cted agen
Prote AG.

lkswage es n
o ot g
byV ua
d ran
ir se
tho tee
or Caddy 2011 ➤
u
ss
a
4-cylinder diesel engineac(1.6 l engine, common rail) - Edition 09.2016
ce
e
nl
pt
du
an
itte
2 Exhaust gas cleaning
y li
erm
ab
ility
ot p
⇒ “2.1 Assembly overview - catalytic converter”, page 329
wit
, is n
h re
⇒ “2.2 Assembly overview - particulate filter”, page 331
hole
spec
es, in part or in w
⇒ “2.3 Removing and installing particulate filter”, page 332
t to the co
2.1 Assembly overview - catalytic converter
rrectness of i
Note
l purpos
nform
ercia

bodywork.
m
at
om
ion
♦ If necessary, loosen double and single clamps and align si‐
c
in t
or
lencers and exhaust pipe so that sufficient clearance is main‐
his
ate
tained to the bodywork and the support rings are evenly loaded
do
priv
c
⇒ page 327 .
um
for
en
ng
t.
♦ The flexible joint in the front exhaust pipe must not be bent
yi Co
op py
more than 10° since otherwise it can be damaged.
t. C rig
gh ht
pyri by
♦ Renew seals, gaskets and self-locking nuts.
co Vo
by lksw
cted agen
Prote AG.
♦ EU3 vehicles have a catalytic converter instead of a particulate
filter.
♦ The following components are not installed on EU3 vehicles.
♦ Exhaust gas pressure sensor 1 - G450- ⇒ Item 1 (page 331)

♦ Exhaust gas temperature sender 3 - G495-
♦ Exhaust gas temperature sender 4 - G648-
♦ Lambda probe - G39- ⇒ Item 5 (page 331)
♦ Bracket ⇒ Item 6 (page 341)
2. Exhaust gas cleaning 329

Caddy 2011 ➤
1 - Catalytic converter
2 - Gasket
sition
3 - Clip
❑ 7 Nm.
4 - Mounting
5 - Nut
❑ 25 Nm.
6 - Holder
❑ Renewing
❑ Particulate filter bracket
with riveted studs ⇒
Electronic parts cata‐
logue .
❑ This is the only way to
apply the necessary agen
AG. Volkswagen AG d
oes
specified torque. Volksw not
gu
d by ara
e
7 - Nut horis nte
eo
ut
❑ 25 Nm. ss a ra
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
The flexible joint in the front exhaust pipe must not be bent more
than 10° since otherwise it can be damaged.
nf
ercia
or
If the catalytic converter is to be re-installed, a transportation lock
m
m
atio
- T10403- -arrow- must always be secured to the flexible joint in

om
n in
front exhaust pipe.

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.

Caddy 2011 ➤
2.2 Assembly overview - particulate filter
Note

bodywork. If necessary, loosen clamping sleeve and align si‐
lencer and exhaust end pipe so that sufficient clearance is
maintained to the bodywork and the support rings are evenly
loaded.
♦ If the particulate filter or the exhaust gas pressure sensor 1 -
G450- has been renewed, it is absolutely necessary to adapt
the exhaust gas pressure sensor 1 - G450-
n AG.using
Volksw⇒
ageVehicle
n AG d
diagnostic tester. olks
wage oes
not
V gu
by ara
♦ The flexible joint of the front
ris exhaust pipe must be secured
ed nte
with transportation lockau-thoT10403- to stop overstretching. eo
ra
ss c
ce
le
un
pt
an
d

itte
y li
erm
sor 1 - G450-
ab
ility
ot p
wit
is n
⇒ page 311
h re
ole,
spec
2 - Connector
t to the co
3 - Nut
❑ 10 Nm.
rrectne
4 - Shield
5 - Lambda probe - G39- with
ss
Lambda probe heater - Z19-
o
cial p
❑ Grease only thread with f inform

high-temperature paste
mer
atio
- G 052 112 A3- .

om
n
c
❑ The high-temperature
i
or
n thi
paste must not get into

te
sd
va
the slots on the probe

i
o
pr
cum
body.
r
fo
en
ng
t.
❑ 52 Nm.
yi Co
Cop py
t. rig
gh ht
yri
⇒ page 308
p by
o Vo
by c lksw
cted agen
Prote AG.
sender 4 - G648-
❑ 45 Nm.
7 - Gasket
sition
8 - Clip
❑ 7 Nm.
sender 3 - G495-
❑ 45 Nm.
10 - Bolt
❑ 25 Nm.

lkswage es n
o ot g
byV ua
d ran
ir se tee
o
Caddy 2011 ➤ auth or
ac
ss
ce
e
nl
pt
du
an
11 - Mounting
itte
y li
erm
ab
❑ Renew if damaged.
ility
ot p
wit
12 - particulate filter
, is n
h re
❑ With oxidation catalytic converter and front exhaust pipe.
hole
spec
❑ After renewing particulate filter, adaptation of ash mass comparison must be set to “0” ⇒ Vehicle diag‐
es, in part or in w
t to the co
nostic tester.
rrectness of i
13 - Bolt
❑ 25 Nm.
l purpos
14 - Holder
nform
ercia
❑ Replacing particulate filter bracket with riveted stud bolt ⇒ Electronic parts catalogue .
m
❑ This is the only way to apply the necessary specified torque.
at
om
ion
c
15 - Holder
in t
or
his
te
❑ Bolted to diesel particulate filter.

a
do
priv
cum
or
16 - Holder
f
en
ng
t.
yi
❑ Bolted to cylinder head.
Co
Cop py
t. rig
gh
17 - Bolt
ht
pyri by
Vo
co lksw
❑ 25 Nm.
by
cted agen
Prote AG.
18 - Bolt
❑ 3 Nm.
19 - Bolt
❑ 3 Nm.
20 - Nut
❑ 8 Nm.
21 - Clamp
2.3 Removing and installing particulate filter


AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
aut
h
Caddy 2011 ➤
ra
s c
ce
le
un
pt
an
d
♦ Engine support - 3300 A-
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
♦ Holder - T10346-
♦ Ring ratchet spanner, 13 mm AF - T10384-

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
♦ Transport lock - T10404-
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
♦ Flange bolt M6x20
om
n
c
i
or
n
Removing
thi
te
sd
va
– Disconnect connector -3- for Lambda probe - G39- and con‐

i
o
pr
cum
r
nector -2- for exhaust gas temperature sender 1 - G235- .

fo
en
ng
t.
yi Co
– Remove Lambda probe ⇒ page 308 . . Cop py
rig
ht ht
rig by
copy Vo
by lksw
cted agen
Prote AG.

separate.
on turbocharger.

Caddy 2011 ➤

bocharger.
– Only loosen bolt -1-.

– Pull connector out of retainers and guide lines out of retainers
on plenum chamber bulkhead -2- and on turbocharger.
– Disconnect electrical connector -2- on exhaust gas pressure

sensor 1 - G450- .
– Unscrew bolts -3- and -4-. AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut 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
– Unclip lines for exhaust gas pressure sensor 1 - G450- to‐

nform
ercia
– Place exhaust gas pressure sensor 1 - G450- on particulate

m
at
om
filter.
ion
c
in t
or
– Remove exhaust temperature sender 3 - G495- with spanner

his
ate
- T10395/6- ⇒ page 343 .

do
priv
cum
or

f
en
ng
t.
yi Co
Cop py
t. rig
– Lower subframe ⇒ Running gear; Rep. gr. 40 ; Subframe .
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

from exhaust pipe downstream of particulate filter.
Note
Disregard -item 2-.
– Unscrew bolts -arrows- and remove heat shield for right drive
shaft. AG. Volkswagen AG d
agen oes
ksw n ol ot g
yV ua
edb ran
ris 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
– Loosen nuts -1- above particulate filter bracket using ratchet
wrench - T10384- .
rrectness of i
– Unscrew nuts -2-.
l purpos
– Remove particulate filter bracket.

Replacing particulate filter bracket with riveted stud bolt ⇒ Elec‐
nf
ercia
tronic parts catalogue (ETKA) .
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
cted agen
Prote AG.
– Unscrew bolts -2- and -3- for pendulum support.
Caution
Risk of damage to flexible joint

♦ Do not bend de-coupling element in front exhaust pipe by
more than 10°.

Caddy 2011 ➤
– Loosen nuts -1- and push clip forwards -arrow-.
– Unscrew nuts and remove rear tunnel cross-piece -3-.

– Only unscrew front mounting on rear part of exhaust system
-1-.
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
– Unscrew clamp washers -2- and -3- and remove heat shield.
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
op
– Remove bolts -arrow-.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted
Caution
agen
Prote AG.
• Do not mount bracing device - 3300 A- on or against sump.

Caddy 2011 ➤
– Bolt bracket - T10346- on securely with bolt -2-.

2 - Flange bolt M6x20
– Secure engine support - 3300 A- on bracket - T10346- .
– Position bracing device - 3300 A- against lower edge of crank‐
case.
– Press engine forwards using spindle of engine support - 3300
A- .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
b ara
Note rise
d
nte
tho eo
au ra
Observe connecting lines, hoses and radiator when moving en‐ ss c
ce
le
gine/gearbox assembly.
un
pt
an
d
itte
y li
erm
ab
– Note the following in particular:
ility
ot p
wit
is n
• Do not allow the air conditioning compressor -2- to touch the
h re
ole,
refrigerant line -1- -arrow-.
spec
• The alternator must not contact the refrigerant line.
t to the co
• The pressure pipe must not contact the radiator.
rrectness o
cial p
f inform
mer
atio
m

o
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.
– Remove particulate filter by turning it 180° around its own axis.

Caddy 2011 ➤
– If the particulate filter is to be re-installed, a transportation lock

- T10403- -arrow- must always be secured to the flexible joint
in front exhaust pipe.
Installing
Note
♦ Renew seals, self-locking nuts and clip for particulate filter.

♦ Attach cable ties in all the same places when installing.
♦ Replacing particulate filter bracket with riveted stud bolt ⇒
Electronic parts catalogue (ETKA) .
♦ This is the only way to apply the necessary specified torque.
Observe sequence when installing particulate filter:
AG. Volkswagen AG d
agen oes
olksw not
b yV gu
ara
ed
ris nte
ho eo
ut ra
1. Position particulate
ss a filter on
-1- turbo charger and loosely attach clip
c
ce
le
2. Screw bolts and nuts -2…5- in by hand

un
pt
an
• It must still be possible to move particulate filter and bracket

d
itte
y li
rm
ab
pe
ility
3. Tighten clip -1-

ot
wit
, is n
4. Tighten nuts and bolts -2- and -5-

h re
hole
5. Tighten nuts and bolts -3- and -4-

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
ht. rig
rig ht
py by
co Vo
by lksw
339
cted agen
Prote AG.
2. Exhaust gas cleaning
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
Caddy 2011 ➤ aut ra
c
s
4-cylinder diesel
s engine (1.6 l engine, common rail) - Edition 09.2016
ce
le
un
pt
an
d
itte
– Make sure that the cables are in the correct position. They are
y li
erm
ab
held in position together on the heat shield by clip -A-.
ility
ot p
– Install cover for underbody ⇒ General body repairs, exterior;
wit
is n
h re
Rep. gr. 50 .
ole,
spec
– Install pendulum support ⇒ page 32 .
t to the co
– Installing exhaust temperature sender 4 - G648-
⇒ page 341 .
rrectne
– Align exhaust system free of stress ⇒ page 327 .
– Install lambda probe - G39- and exhaust gas pressure sensor
ss
1 - G450- ⇒ page 308 .
o
cial p
f in
If the particulate filter or the exhaust gas pressure sensor 1 -
form
mer
G450- has been renewed, it is absolutely necessary to adapt the
atio
exhaust gas pressure sensor 1 - G450- using ⇒ Vehicle diagnostic
om
n
tester.
c
i
or
n thi
te
sd
Torque settings
iva
o
pr
cum
r

fo
en
ng
t.
yi Co
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐ Cop py
t. rig
tion”, page 341 opyri
gh by
Vo
ht
by c lksw
♦ ⇒ “1.1 Assembly overview - silencers”, page 325 Prote
cted AG.
agen

Caddy 2011 ➤
3 Exhaust gas temperature regulation

⇒ “3.1 Assembly overview - exhaust gas temperature regulation”,
page 341
⇒ “3.2 Removing and installing exhaust gas temperature sender
1 G235 ”, page 342
3 G495 ”, page 343
4 G648 ”, page 345
3.1 Assembly overview - exhaust gas temperature regulation
Caution
Threads of exhaust gas temperature sender -G495- and -

G648- are coated. Do NOT additionally grease with high-
temperature paste and always adhere to the prescribed
tightening torque. Otherwise, the threaded connection can be‐
come loose and subsequent failures can then occur.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
1 - Exhaust turbocharger rised ara
nte
ho eo
2 - particulate filter aut ra
ss c
❑ Assembly overview
ce
le
un
pt
⇒ page 331
an
d
itte
y li
rm
ab
pe
⇒ page 332
ility
ot
wit
, is n
3 - Nut
h re
hole
❑ 9 Nm.
spec
es, in part or in w
t to the co
4 - Holder
❑ Bolted to diesel particu‐
late filter.
rrectness of i
5 - Hose
l purpos
6 - Holder
❑ For exhaust gas pres‐
nform
ercia
sure sensor 1 - G450-

m
a
com

ion in
sor 1 - G450-
r
te o
thi

s
iva
do
r
⇒ page 311
rp
cum
fo
en
g
8 - Holder
n
t.
yi Co
Cop py
.
9 - Bolt
ht rig
rig ht
py by
Vo
❑ 4.5 Nm.
co lksw
by
cted agen
Prote AG.
10 - Bolt
❑ 8 Nm.
sender 3 - G495-
❑ Thread of sender is
coated.
grease.
3. Exhaust gas temperature regulation 341

Caddy 2011 ➤
❑ 45 Nm.
❑ Removing and installing ⇒ page 343 AG. Volkswagen AG d
agen oes
lksw not
12 - Lambda probe - G39- d by
Vo gu
ara
e nte
❑ Grease only thread with high-temperature paste -thG
o 052 112 A3- . High-temperature paste must
ris
e onot get
into the slots on the probe body. s au ra
c
s
❑ 52 Nm.
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
❑ Thread of sender is coated.
wit
, is n
h re
❑ Do not additionally oil or grease.
hole
spec
❑ 45 Nm.
es, in part or in w
t to the co
rrectness of i
❑ 45 Nm.
l purpos
nform
ercia
3.2 Removing and installing exhaust gas

m
at
om
i
temperature sender 1 - G235-
on
c
in t
or
his
e

at
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Removing
wage es n
– Disconnect connector -2- for yV
oexhaust gas temperature sender
lks ot g
ua
1 - G235- . ed b ran
oris tee
h
– Remove noise insulation
aut
⇒ General body repairs, exterior; or
ac
ss
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le
un
pt
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d
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erm
ab
ility
ot p
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spec
t to the co
– Unscrew exhaust temperature sender 1 - G235- -1- and re‐
rrectne
move from exhaust manifold from below.
ss o
Note
cial p
f inform
mer
-Arrows- can be disregarded.
atio
om
n
c
i
or
n
Installing
thi
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fo
en
– Attach cable ties in all the same places when installing.
ng
t.
yi Co
op py
Installation position of exhaust gas temperature sender -G235- .
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ht ht
rig by
copy Vo
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• Angled shaft must have a distance -a- = 3 … 5 mm to bolting cted agen
Prote AG.
of turbocharger support.
WARNING
The torque wrench - V.A.G 1331- must be set to 28 Nm in this

case.
Extending the torque wrench - V.A.G 1331- with the spanner
from tool set - T10395/7- allows the correct torque of 45 Nm to
be achieved.
– Then, tighten using torque wrench - V.A.G 1331- together with

wrench from tool set - T10395/7- .
Torque settings
tion”, page 341


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Caddy 2011 ➤ thor eo
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ab
ility
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spec
t to the co
rrectness o
cial p
f inform
♦ Tool insert, AF 17 mm - T10395- mer
atio
om
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c
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en
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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.
Caution
Thread of exhaust gas temperature sender 3 - G495- is coated.

Do NOT additionally grease with high temperature paste and
always adhere to the prescribed tightening torque
⇒ page 341 . Otherwise, the threaded connection can become
loose and subsequent failures can then occur.
Removing
– Remove Lambda probe - G39- ⇒ page 308 .
– Disconnect electrical connector -1- for exhaust temperature
sender 3 - G495- and free electrical line.
Note

Caddy 2011 ➤
– Unscrew exhaust gas temperature sender 1 - G495- in direc‐

tion opposite to direction of -arrow-.
Installing
Install in reverse order, noting the following: agen
AG. Volkswagen AG d
oes
olksw not
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– Attach cable ties in all the same places ed when installing.
by ara
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ris
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rm
ab
pe
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ot
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Installation position of exhaust temperature sender 3 - G495-
h re
hole
-item 1-:
spec
es, in part or in w
• Angled end facing left side of vehicle.
t to the co
• Angle -α- to mark -arrow- = approx. 17°.
rrectness of i
WARNING
l purpos
The torque wrench - V.A.G 1331- must be set to 29 Nm in this
nform
ercia
case.
m
Extending the torque wrench - V.A.G 1331- with the spanner
a
com
tio
from tool set - T10395/6- allows the correct torque of 45 Nm to
n in
r
be achieved.
te o
thi
s
iva
do
r
rp
cum
fo
– Lubricate thread of sender using high-temperature paste - G
en
ng
t.
yi
052 112 A3- .
Co
Cop py
ht. rig
rig ht
py by
– Screw exhaust temperature sender 1 - G495- in by hand. co Vo
by lksw
cted agen
Prote AG.
– Then apply tightening torque using torque wrench - V.A.G
1331- together with wrench from tool set - T10395/6- .
– Install Lambda probe - G39- ⇒ page 308 .
Torque settings
tion”, page 341


Caddy 2011 ➤
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Caution
s
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nl
pt
du
an
Thread of exhaust gas temperature sender 4 - G648- is coated.

itte
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erm
Do NOT additionally grease with high temperature paste and

ab
ility
always adhere to the prescribed tightening torque

ot p
wit
⇒ page 341 . Otherwise, the threaded connection can become

, is n
h re
loose and subsequent failures can then occur.

hole
spec
es, in part or in w
t to the co
Removing
rrectness of i

separate.
l purpos
– Disconnect electrical connector -1- and free electrical wiring.

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.

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o
auth or
ac Caddy 2011 ➤
ss 4-cylinder diesel engine (1.6 l engine, common rail) - Edition 09.2016
ce
e
nl
pt
du
an
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-
itte
y li
from exhaust pipe downstream of particulate filter.
erm
ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Disregard -item 2-.
t to the co
Installing
rrectness of i
l purpos
Torque settings
nf
ercia
o
tion”, page 341
rm
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
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by
cted agen
Prote AG.

Caddy 2011 ➤
4 Exhaust gas recirculation

⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 348
⇒ “4.2 Checking changeover for exhaust gas recirculation cooler”,
page 349
⇒ “4.3 Removing and installing exhaust gas recirculation cooler”,
page 350
⇒ “4.4 Checking exhaust gas recirculation cooler for leaks”, page
353
4.1 Assembly overview - exhaust gas recirculation
1 - Bolt
❑ 9 Nm.
pipe
of cracking
3 - Bolt
❑ 9 Nm.
4 - Gasket
❑ Renew after removal AG. Volkswagen AG d
agen oes
lksw not
5 - Vacuum line by Vo gu
ara
d
❑ Do not alter shape. rise nte
tho eo
u ra
❑ Vacuum hose connec‐ ss a c
tion diagram
ce
le
un
pt
⇒ page 259
an
d
itte
6 - Bolt y li
rm
ab
pe
ility
❑ 9 Nm.
ot
wit
, is n
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7 - Gasket
hole
spec

es, in part or in w
t to the co

pipe
rrectness of i

l purpos
of cracking
9 - Bolt
nform
ercia
❑ 9 Nm.
m
10 - Clip
com
tion in
❑ 4 Nm.
r
te o
thi
s
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do

r
rp
cooler
um
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ng
t.
❑ With integrated exhaust gas recirculation valve 1 - GX5-
yi Co
Cop py
❑ Checking changeover ⇒ page 349 .
t. rig
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cted agen
Prote AG.
12 - Bolt
❑ 9 Nm.

Caddy 2011 ➤
13 - Gasket
14 - Gasket
15 - Exhaust gas recirculation pipe
❑ With flexible joint; do not bend flexible joint - risk of cracking
16 - Nut
❑ 24 Nm.
17 - Bolt
❑ 9 Nm. AG. Volkswagen AG d
agen oes
ksw
18 - Gasket byV
ol not
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ara
ed
❑ Renew after removal horis nte
eo
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ce
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un
pt
4.2 Checking changeover for exhaust gas
an
d
itte
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recirculation cooler
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
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pr
c
um
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fo
en
ng
t.
– Raise vehicle on lift.
yi Co
Cop py
ht. rig
– Pull off heat protection -2- from vacuum servo element. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
4. Exhaust gas recirculation 349

Caddy 2011 ➤
– Pull off vacuum hose -1- from vacuum servo element and con‐
nect hand vacuum pump - VAS 6213- in its place.
– Operate hand vacuum pump to create a vacuum.
• The linkage of the changeover for the exhaust gas recircula‐
tion cooler moves -arrows-.
If linkage does not move or only moves in jerks:
♦ Vacuum actuator is defective.
♦ Changeover flap for exhaust gas recirculation is tight.
– Fit heat shield sleeve in the same place when installing.
4.3 Removing and installing exhaust gas re‐

circulation cooler

AG. Volkswagen AG d
agen oes
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ility
ot
wit
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hole
spec
es, in part or in w
t to the co

rrectness of i
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nform
mercia
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com
tion in
r
te o
thi
s
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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 ➤
Removing
– Remove particulate filter ⇒ page 332 .
case.
– Move clear vacuum hoses -arrows-.
– Remove air pipe from air filter housing; release hose clip -3-
for this.
– Unscrew bolt -2-, swing air pipe with inlet connection to rear
and pull off from turbocharger.
– Loosen hose clip -1- and remove pulsation damper -2-.

– Unscrew bolts -arrows-. AG. Volkswagen AG d
agen oes
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V gu
d by ara
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or eo
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nl
pt
du
an
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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
– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
lation.
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Unscrew bolts -1, 3-, union nutV-2- and banjo bolts -4, 5-, and
olkswagen AG
remove turbochargerssupport
wage
n AG.with oil supplydoline.
es k not
y Vol gu
– Place drip tray
se
d- bVAS 6208- beneath engine. ara
nte
ri
utho eo
ra
a c
ss
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
– Clamp off coolant hoses -1- and -3- with hose clamps to 25 mm
- 3094- , loosen hose clips and remove hoses from exhaust
gas recirculation cooler.
rrectne
ss
– Remove vacuum hose -4- from vacuum unit and free.
o
cial p
f inform
– Unscrew bolts -arrows- and remove exhaust gas recirculation
mer
cooler.
atio
om
n
Installing
c
i
or
n thi
te

sd
iva
o
pr
cum
r
fo
en
ng
t.
yi
Note
Co
Cop py
t. rig
gh ht
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♦ Renew gaskets, seals, O-rings and self-locking nuts ⇒ Elec‐ cop Vo
by lksw
tronic parts catalogue (ETKA) . cted agen
Prote AG.
– Fit heat shield sleeve in the same place when installing.

– Installing support for turbocharger with oil supply line, inlet
connection and pulsation damper ⇒ page 222 .

bocharger. -arrow-.
– Install particulate filter ⇒ page 332 .
– Checking engine oil level ⇒ page 165 .
– Check coolant level ⇒ page 187 .
Torque settings
♦ ⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 348
tion”, page 341

Caddy 2011 ➤
4.4 Checking exhaust gas recirculation

cooler for leaks
The exhaust gas recirculation cooler is checked for leaks with
⇒ Vehicle diagnostic tester.
– Connect ⇒ Vehicle diagnostic tester to the vehicle.
– Select test program and follow instructions ⇒ Vehicle diag‐
nostic tester, 01 - 4-cylinder diesel engine J623 , 19
- Cooling , Sub-systems, constraints , Cooling system
leaks .
lkswage es n
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byV ua
d ran
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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
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.

Caddy 2011 ➤ gen AG
. Volkswagen AG
does
swa
4-cylinder diesel engine (1.6 l engine, common rail) y-VEdition 09.2016
olk not
gu b ara
ed nte
oris e
th or
28 – Glow plug system
au ac
ss
ce
e
nl
pt
du
an
itte
y li
1 Glow plug system
erm
ab
ility
ot p
⇒ “1.1 Removing and installing glow plug”, page 354
wit
, is n
h re
hole
⇒ “1.2 Checking glow plugs”, page 356
spec
es, in part or in w
⇒ “1.3 Removing and installing automatic glow period control unit
t to the co
J179 ”, page 356
⇒ “1.4 Removing and installing engine speed sender G28 ”, page
rrectness of i
356 l purpos
⇒ “1.5 Removing and installing Hall sender G40 ”, page 357
1.1 Removing and installing glow plug
nform
ercia

m
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.
♦ 10 mm jointed spanner - 3220-
♦ Pliers - 3314-
354 Rep. gr.28 - Glow plug system

Caddy 2011 ➤
Removing
– Clean glow pin plug opening in cylinder head. It must be en‐
sured that no dirt falls into the cylinder when this is being done.
Note
♦ Cleaning procedure:
♦ Use a vacuum cleaner to remove coarse dirt.
♦ Spray brake cleaner or suitable cleaning agent into glow plug
opening, let it work in briefly and blow out with compressed air.
♦ Then use an oil-soaked cloth to clean the glow pin plug open‐
ing.
– Pull connector -B- off exhaust gas pressure sensor 1 - G450-

and fuel pressure sender - G247- -C-.
– Undo bolts -arrows- of coolant line at intake manifold and put
line down in front of intake manifold.
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
y li
erm
ab
ility
ot p
– Open cable guide catches to lay wiring harness to side.
wit
is n
h re
ole,
spec
Caution
t to the co
connecting the heater-element connectors.
rrectne
Otherwise the whole wiring harness will need to be renewed.
Do not close the pliers - 3314- too firmly when pulling the glow
ss
plug connectors off as otherwise the support sleeve can be
o
cial p
damaged. f inform
mer
atio
om
n
c

i
or
n thi
e
shoulder -arrow B- and pull connectors off glow plugs.

t
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.
1. Glow plug system 355

Caddy 2011 ➤
– Unscrew nut of fuel return line at intake manifold. Open clip

-arrow- and pull line off fuel rail.
– Remove complete return line and put it down in front of intake
manifold. en AG. V
olkswagen AG
ag does
lksw not
– To loosen glow plugs, use special tool U/J extension
yV
o
and gu
db ara
10 mm socket - 3220- . orise nte
th eo
Installing s au ra
c
s
ce
le

un
pt
an
d
itte
y li
Torque settings
rm
ab
pe
ility
ot
wit
, is n
h re
Glow plug 18 Nm.
hole
spec
es, in part or in w
t to the co
1.2 Checking glow plugs
Check
rrectness of i
The glow plug system is monitored by the engine control unit's
l purpos
self-diagnosis system.
Necessary checks are performed using ⇒ Vehicle diagnostic test‐ nform
ercia
er.
m
1.3 Removing and installing automatic glow

com
tion in
period control unit - J179-

r
te o
thi
s
iva
do
Removing
r
rp
cum
fo
en
g
– Remove battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery;

n
t.
yi Co
op
Removing and installing battery tray . C py
t. rig
gh ht
yri
– Pull out relay carrier -2- in -direction of arrow- from underneath
p by
o Vo
by c lksw
electronics box in engine compartment. Prote
cted AG.
agen

– Remove automatic glow period control unit - J179- -1-.
Installing
Install in reverse order of removal.
1.4 Removing and installing engine speed

sender - G28-

lkswage es n
o ot g
byV ua
ir se
d ran
te Caddy 2011 ➤
o
auth 4-cylinder diesel engine (1.6 el oengine,
ra common rail) - Edition 09.2016
ss 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
rrectness o
cial p
f in
♦ Hexagon key extension, 4 mm - T10370-
form
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.
Removing
– Detach electrical connector -1- from engine speed sender -
G28- by hand.
– Unscrew securing bolt -arrow- using socket 4 mm - T10370-

and remove engine speed sender - G28- .
Installing
Torque settings
1.5 Removing and installing Hall sender -

G40-

Caddy 2011 ➤
Removing
– Undo nuts -3-.
– Remove hose retainer -4- from fuel filter.
– Place fuel filter -7- aside (fuel hoses -5 and 6- remain connec‐
ted).
– Remove vibration damper ⇒ page 64 .
– Remove toothed belt from idler pulley and high-pressure pump
⇒ page 121 .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ho eo
aut ra
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un
pt
an
d
itte
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rm
ab
pe
ility
– Detach connector from retainer.
ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
Disregard items -2 and 3-.
rrectness of i
l purpos
nform
ercia
– Remove idler roller -1-.

m
a
com
tio
– Using a screwdriver, remove webs -arrows- and move wiring

n in
r
harness aside.
te o
thi
s
iva
do
– Remove cover -2- of repair aperture.

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 ➤
– Screw off Hall sender - G40- -arrow-.

– Pull wiring harness together with Hall sender - G40- through
repair aperture to remove.
Installing
♦ Seal repair aperture in toothed belt guard with rubber kswplugs as
age es n
specified in ⇒ Electronic parts catalogue (ETKA) y Vo.l ot g
ua
db e ran
ris tee
– Fit toothed belt and adjust the valve timing
ut ⇒ page 121
ho . or
a ac
ss
Torque settings
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
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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.

D3E802E92D9-4-Cylinder Diesel Engine (1 6 L Engine Common Rail)

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D3E802E92D9-4-Cylinder Diesel Engine (1 6 L Engine Common Rail)

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Service

Service Department. Technical Information

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E802E92D9

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

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2 Removing and installing motor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.3 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.4 Supporting engine in installation position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.5 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.1 Assembly overview - cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.5 Assembly overview - ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.6 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

1.7 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.2 Removing and installing toothed belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3 Valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

3.1 Assembly overview - valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

3.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

2.5 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . . 204

3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

4.2 Removing and installing lower coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

3.1 Overview - fuel return lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

6 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

6.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

8.1 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

8.5 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316

8.6 Checking fuel pressure sender G 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

8.7 Checking fuel metering valve N 290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

9 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

4.3 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 350

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

⇒ “1.2 Safety regulations for working on fuel supply”, page 2

struments during a road test”, page 3

Hot steam may escape when expansion tank is opened. Wear

eye protection and protective clothing to avoid eye injuries and

♦ Cooling system is pressurized when engine is warm. If nec‐

1.2 Safety regulations for working on fuel

When doing any repair work, especially in the engine compart‐

the system, wrap a cloth around the connection and care‐

fully loosen to release the pressure!

♦ Wear eye and hand protection when performing any type

of repair work on the fuel system!

When removing and installing fuel gauge sender or fuel pump

♦ Place the suction hose of an activated exhaust gas extraction

tract any fuel vapours that are released. If no exhaust gas

♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!

1.3 Safety precautions when using testers