D3E802F2683-4-Cylinder Diesel Engine (2 0 L Engine Common Rail)

Service
Workshop Manual
Caddy 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail)
Engine ID
CFH CFH CFH CLC CFJA CLC
C E F A B
Edition 09.2016
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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
28 - Glow plug system
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Technical information should always be available to the foremen and mechanics, because their
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D3E802F2683

Caddy 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 09.2016
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Engine number/engine data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Safety regulations for working on fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Safety precautions when working on injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Safety precautions when working on the cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Safety precautions when working on charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 General safety provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Repair notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 General notes on the lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Rules for cleanliness when working on fuel supply system or injection system . . . . . . . . . . 7
3.3 Rules for cleanliness during work on fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.4 General repair notes for working on fuel systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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10 - Removing and by V installing engine . . . . . t.gu.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1.2 Separating engine from gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
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1.3 Separating engine from dual clutch gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1.4 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2 Assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

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2.2 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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2.3 Removing and installing motor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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 - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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1.2 Assembly overview - ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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1.3 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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1.4 Assembly overview - poly V-belt drive with air conditioning compressor . . . . . . . . . . . . . . 52
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1.5 Assembly overview - poly V-belt drive without air conditioner compressor . . . . . . . . . . . . 53
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1.6 Removing and installing poly V-belt, vehicles with air conditioner . . . . . . . . . . . . . . . . . . . . 53
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1.7 Removing and installing tensioner for poly V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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1.8 Removing and installing bracket for ancillaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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1.9 Removing and installing vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
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1.10 Removing and installing engine bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.11 Renewing crankshaft oil seal - belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.12 Removing and installing sealing flange on pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 Cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.1 Assembly overview - cylinder block, gearbox end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.2 Removing and installing flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.3 Removing and installing sealing flange on gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3 Pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.1 Assembly overview - pistons and conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.2 Checking pistons and cylinder bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.3 Piston and cylinder dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.4 Measuring piston projection at TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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3.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.6 Separating new conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.7 Removing and installing oil spray jets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.1 Assembly overview - crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
4.2 Crankshaft dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.3 Measuring axial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.4 Measuring radial clearance of crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.5 Renewing needle bearing in crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
4.6 Renewing spur gear for crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1 Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.1 Assembly overview - cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
1.2 Assembly overview - cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
1.3 Removing and installing cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.4 Removing and installing cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.5 Removing and installing vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
1.6 Checking compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
2 Toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Assembly overview - toothed belt drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.2 s Measuring axial clearance of camshaft . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

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3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

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3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

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3.7 Renewing valve stem seals with cylinder head installed . . . . . . . . . . . . . . . . . . . . . . . . . . 153
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3.8 Renewing valve stem seals with cylinder head removed . . . . . . . . . . . . . . . . . . . . . . . . . . 157
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4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

4.1 Reworking valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.2 Checking valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
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4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

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4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
17 - Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
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1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

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1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

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1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

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1.4 Removing and installing oil pump, with balancer shaft module . . . . . . . . . . . . . . . . . . . . . . 171
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1.5 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

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1.6 Removing and installing oil level and oil temperature sender G266 . . . . . . . . . . . . . . . . . . 172
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2 Oil filter, oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
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2.1 Assembly overview - oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . .
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2.2 Removing and installing oil filter housing with engine oil cooler . . . . . . . . . . . . . . . . . . . . . . 175
2.3 Removing and installing oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.4 Checking oil pressure switch F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
2.5 Checking oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
2.6 Measuring oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.1 Removing and installing engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4 Balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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4.1 Assembly overview - balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
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4.2 Removing balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
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4.3 Installing a new balancer shaft module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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4.4 Installing a previously used balancer shaft module again . . . . . . . . . . . . . . . . . . . . . . . . . . 196
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5 Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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5.1 Assembly overview - oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
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5.2 Removing and installing oil line for turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
19 - Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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1 Cooling system/coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
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1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1.2 Coolant hose connection diagram, gearbox side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
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1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

1.4 Checking cooling system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
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1.5 Checking engine oil cooler for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
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2 Coolant pump, regulation of cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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2.1 Assembly overview - coolant pump, thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
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2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

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2.3 Removing and installing 4/2-way valve with thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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2.4 Removing and installing coolant temperature sender G62 . . . . . . . . . . . . . . . . . . . . . . . .
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2.5 Removing and installing radiator outlet coolant temperature sender G83 . . . . . . . . . . . . 222
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3 Radiator, radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
AG.
3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

3.2 Removing and installing radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
3.3 Removing and installing radiator cowl with radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
4 Coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.1 Assembly overview - coolant pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
4.2 Removing and installing front coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
4.3 Removing and installing upper front coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.4 Removing and installing left coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4.5 Removing and installing right coolant pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
21 - Turbocharging/supercharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1 Charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.1 Assembly overview - charge air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
1.2 Assembly overview - charge-air hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
1.3 Hose connections with screw-type clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.4 Removing and installing charge air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
1.5 Removing and installing charge air pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
1.6 Removing and installing charge air pressure sender G31 / intake air temperature sender G42
...................................................................... 244
1.7 Checking charge air system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
2 Exhaust turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.1 Assembly overview - turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
2.2 Removing and installing turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
2.3 Replacing vacuum unit with position sender for charge pressure positioner G581 . . . . . . 258
2.4 Removing and installing charge pressure control solenoid valve N75 . . . . . . . . . . . . . . . . 264
23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

1 Injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.1 Schematic overview - fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
1.2 Overview of fitting locations - injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
1.3 Checking fuel system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
1.4 Filling and bleeding fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
2 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Contents iii
Caddy 2011 ➤
2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

2.2 Checking vacuum system agen . . . . . . . . . . A
AG. Volkswagen . G . d. o.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
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3 Injectors/high-pressure
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3.1 Assembly toverview
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ris - fuel rail and injectors . . . . . . . .nt.ee.o. . . . . . . . . . . . . . . . . . . . . . . . . . 288
3.2 Adapting au
ss correction values for injectors . . . . . . . . . . . . . . .c . . . . . . . . . . . . . . . . . . . . . . . . . 290
ra
3.3 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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3.4 Checking return flow rate of injectors with engine running . . . . . . . . . . . . . . . . . . . . . . . . . . 291
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3.5 Checking return flow rate of injectors at starter speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
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3.6 Checking for injectors sticking open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
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3.7 Checking low pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
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3.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
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3.9 Removing and installing high-pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
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3.10 Removing and installing fuel rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
3.11 Removing and installing injector seal in cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . 313
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4 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
4.1 Assembly overview - high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
l purpos
4.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

5 Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321
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5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

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5.2 Removing and installing intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
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5.3 Removing and installing throttle valve module J338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
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6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

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Removing and installing exhaust gas pressure sensor 1 G450 . . . . . . . . . . . . . . . . . . . .um 327
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6.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

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6.3 Checking fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
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6.4 Removing and installing fuel pressure regulating valve N276 . . . . . . . . . . . . . . . . . . . . . . 330
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6.5 Removing and installing fuel pressure sender G247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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334
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7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

7.1 Removing and installing Lambda probe G39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
8 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
8.1 Assembly overview - air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
8.2 Removing and installing air filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
9 Engine (motor) control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
9.1 Removing and installing engine (motor) control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 343
9.2 Removing and installing anti-theft engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . 344
26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

1 Exhaust pipes, silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
1.1 Assembly overview - silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
1.2 Cutting exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
1.3 Aligning exhaust system free of stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
1.4 Installation position of clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
2 Exhaust gas cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
2.1 Assembly overview - particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
2.2 Assembly overview - catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
2.3 Removing and installing particulate filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
3 Exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3.1 Assembly overview - exhaust gas temperature regulation . . . . . . . . . . . . . . . . . . . . . . . . . . 363
3.2 Removing and installing exhaust gas temperature sender 1 G235 . . . . . . . . . . . . . . . . . . 364
4 Exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
4.1 Assembly overview - exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
4.2 Removing and installing exhaust gas recirculation cooler . . . . . . . . . . . . . . . . . . . . . . . . . . 370
iv Contents
Caddy 2011 ➤
n AG.4-cylinder
Volkswagen diesel
AG do engine (2.0 l engine, common rail) - Edition 09.2016
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4.3 Checking
ir se
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ran
tee cooler . . . . . . . . . . . . . . . . . . . . . . . . 372
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4.4 au Checking exhaust gas recirculation cooler for oleaks
th
ra ............................ . . 373
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28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

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1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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1.1 Removing and installing glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
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1.2 Removing and installing automatic glow period control unit J179 . . . . . . . . . . . . . . . . . . . . 376
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1.3 Removing and installing engine speed sender G28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
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spec
1.4 Removing and installing Hall sender G40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
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Contents v
Caddy 2011 ➤
AG. Volkswagen AG d
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vi Contents
Caddy 2011 ➤
AG. Volkswagen AG d
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00 – Technical data
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Identification c
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(VRL009251; Edition 09.2016)
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⇒ “1.1 Engine number/engine data”, page 1
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1.1 Engine number/engine data
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The first 3 digits show the mechanical design of engine and are
es, in part or in w
stamped on the engine as previously. The fourth digit shows the
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engine output and varies according to engine control unit. The
four-digit engine code can be found on the identification plate, the
vehicle data sticker and on the engine control unit.
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The engine number (“code letters” and “serial number”) -arrow-
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can be found on the joint between engine and gearbox.

In addition, there is a sticker on the toothed belt guard with “engine
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code” and “serial number”.
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The engine codes can also be found on the vehicle data sticker.
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The engine number consists of up to 9 characters (alphanumeric).

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The first part (maximum 4 characters) makes up the “engine

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code”, and the second part (6 characters), the “serial number”. If

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more than 999,999 engines with the same engine code are pro‐
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duced, the first of the six characters is replaced with a letter.
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Identification code Prote
CFHC CFHE CFHF CFJA
AG.
Manufactured 08.10 08.10 04.10 08.10

Exhaust emissions fulfil These engines comply with the threshold values of the EU5 ex‐
haust emissions standard.
Displacement l 2.0 2.0 2.0 2.0
Power kW at rpm 103/4200 62/ 81/ 125/4200
3000 ... 4600 2750 ... 4200
Torque Nm at rpm 320/ 200/ 280/ 350/
1750 ... 2500 1750 ... 2750 1750 ... 2500 1750 ... 2500
Bore Diameter, mm 81.0 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Valves per cylinder 4 4 4 4
Compression ratio 16.0 16.0 16.0 16.0
Fuel, acc. to DIN EN 590 DIN EN 590 DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
Balancer shaft module No No No No
Catalytic converter Yes Yes Yes Yes
Exhaust gas recirculation Yes Yes Yes Yes
Charging Yes Yes Yes Yes
Intercooler Yes Yes Yes Yes
particulate filter Yes Yes Yes Yes
Identification code CLCB CLCA

Manufactured 11.10 08.10
Exhaust emissions fulfil EU4 standard EU4 standard
Displacement l 2.0 2.0
1. Identification 1
Caddy 2011 ➤
Identification code CLCB CLCA

Power kW at rpm 103/4200 81/4200
Torque Nm at rpm 320/ 250/
1750 ... 2500 1500 ... 2500
Bore Diameter, mm 81.0 81.0
Stroke mm 95.5 95.5
Valves per cylinder 4 4
Compression ratio 16.0 16.0
Fuel, acc. to DIN EN 590 DIN EN 590
Firing order 1-3-4-2 1-3-4-2
Balancer shaft module No No
Catalytic converter Yes Yes
Exhaust gas recirculation Yes Yes
Charging Yes Yes
Intercooler Yes Yes
particulate filter No No
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2 Rep. gr.00 - Technical data

Caddy 2011 ➤
2 Safety information
⇒ “2.1 Safety regulations for working on fuel supply”, page 3
⇒ “2.2 Safety precautions when working on injection system”,
page 4
⇒ “2.3 Safety precautions when working on the cooling system”,
page 4
⇒ “2.4 Safety precautions when working on charge air system”,
page 6
⇒ “2.5 General safety provisions”, page 6
2.1 Safety regulations for working on fuel

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AG. Volkswagen AG d
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When doing any repair work, especially
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ment, pay attention to the following
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due to the cramped condi‐ c
tions:
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♦ Route lines of any kind so that the original routing can be
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restored.
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♦ Ensure sufficient clearance to all moving or hot compo‐
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♦ The fuel and the fuel lines in the fuel system can become
es, in part or in w
very hot (danger of scalding)!
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♦ The fuel system is also under pressure! Before opening
the system, wrap a cloth around the connection and care‐
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fully loosen to release the pressure!
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♦ Wear eye and hand protection when performing any type

of repair work on the fuel system!
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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
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♦ Place the suction hose of an activated exhaust gas extraction

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system close to the assembly opening of the fuel tank to ex‐

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tract any fuel vapours that are released. If no exhaust gas
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extraction system is available, a radial fan with a displacement
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♦ Prevent skin contact with fuel! Wear fuel-resistant gloves!
2. Safety information 3
Caddy 2011 ➤
2.2 Safety precautions when working on in‐

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

ment, pay attention to the following due to the cramped condi‐
tions:
restored.
nents.
WARNING
Risk of injury due to automatic start of engine on vehicles with

a start/stop system.
♦ In vehicles with an activated start/stop system (indicated
by a message in the dash panel insert), the engine may
start automatically. . Volkswagen AG
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♦ Therefore, ensure that the start/stop system is deactivated
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Note the following if testers and measuring instruments have to
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♦ Test equipment must always be secured on the rear seat and
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operated by a 2nd person.
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If test and measuring instruments are operated from front pas‐
spec
senger seat and the vehicle is involved in an accident, there is a
t to the co
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
To prevent injuries to persons and/or destruction of the injection rrectne
and glow plug system, the following must be noted:
s
♦ The ignition must be switched off before connecting or dis‐

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connecting preglow and injection system wiring as well as test

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equipment leads.
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♦ Disconnecting and connecting the battery must only be done

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with the ignition switched off, as otherwise the control unit for
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2.3 Safety precautions when working on the

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Hot steam may escape when expansion tank is opened. Wear
eye protection and protective clothing to avoid eye injuries and
scalding. Cover cap with a cloth and carefully open.

Caddy 2011 ➤
Caution
Please observe the following points during all installation work,

in particular in the engine compartment, due to the space lim‐
itations:
♦ Route all kinds of lines (e.g. for fuel, hydraulics, activated
charcoal system, coolant and refrigerant, brake fluid, vac‐
uum) and electrical cables so that the original line routing
is re-established.
♦ To avoid damage to lines, ensure sufficient clearance from
all moving or hot components.
lkswage es n
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hole
spec
es, in part or in w
Note
t to the co
♦ Cooling system is pressurized when engine is warm. If nec‐
essary, release pressure before carrying out repairs.
rrectness of i
♦ Hose connections are secured with spring-type clips. In case
l purpos
of repair, only use spring-type clips.

♦ For fitting spring-type clips, hose clip pliers - VAS 6340- or
nf
ercia
♦ hose clip pliers - VAS 6362- are recommended. orm

m
atio
om
n in
♦ When installing coolant hoses, route stress-free so that they

or c
do not come into contact with other components (observe

thi
te
sd
a
markings on coolant connection and hose).

iv
o
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o
♦ The arrows on the coolant pipes and on the ends of the hoses
f
en
ng
t.
yi
must be aligned with each other.
Co
Cop py
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Test for leaks in cooling system using cooling system tester - cop Vo
by lksw
V.A.G 1274/- and adapter for expansion tank - V.A.G 1274/8- and cted agen
Prote AG.
adapter for sealing cap - V.A.G 1274/9- .
2. Safety information 5
Caddy 2011 ➤
2.4 Safety precautions when working on

charge air system
WARNING

itations:
restored.
nents.
Note the following if testers and measuring instruments have to

be used during a road test:
♦ Test equipment must always be secured on the rear seat and
operated by a 2nd person.
If test and measuring instruments are operated from front pas‐
senger seat and the vehicle is involved in an accident, there is a
possibility that the person sitting in this seat may receive serious
injuries when the airbag is triggered.
2.5 General safety provisions

♦ 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‐
AG. Volkswagen AG d
ning. lkswagen oes
n o ot g
yV ua
♦ Always switch off the ignitionrisebefore
db connecting or discon‐ ran
tee
necting injection and glowutplug
ho system wiring or tester cables. or
sa ac
♦ Always switch off ignition
s before cleaning engine.
ce
le
un
pt
♦ The battery should only be disconnected and reconnected

an
d
itte
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with ignition switched off.

erm
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ility
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♦ Certain tests may lead to a fault being detected by the control

wit
is n
unit and stored. Therefore, after completing all checks and re‐
h re
ole,
pairs, the fault memory must be read and if necessary cleared.

spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
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Cop py
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by c lksw
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Prote AG.

Caddy 2011 ➤
3 Repair notes
⇒ “3.1 General notes on the lubrication system”, page 7
⇒ “3.2 Rules for cleanliness when working on fuel supply system
or injection system”, page 7
⇒ “3.3 Rules for cleanliness during work on fuel system”,
page 8
⇒ “3.4 General repair notes for working on fuel systems”,
page 8
3.1 General notes on the lubrication system
Note
The oil level must remain below the max. mark - danger of dam‐
age to catalytic converter!
Caution n AG. Volkswagen AG do

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Finding metal shavings or a large or quantity of small metal par‐
is tee
ticles during engine repair could
auth
indicate that the crankshaft or
ac
bearings or conrod bearings are damaged. To prevent this
ss
ce
le
from causing further damage, perform the following repairs:

un
pt
an
d
itte
♦ Thoroughly clean oil passages,
y li
erm
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ility
♦ Renew oil spray jets,
ot p
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♦ Renew engine oil cooler,
h re
ole,
spec
♦ Renew oil filter element.
Drain engine oil ⇒ Maintenance ; Booklet 39 ; Engine oil: Drain t to the co

rrectne
or extract; renew oil filter and replenish engine oil .
Engine oil specifications ⇒ Maintenance ; Booklet 39 ; Service
s
tables
s o
cial p
f in
Oil capacities ⇒ Maintenance ; Booklet 39 ; Service tables

form
mer
Checking engine oil level ⇒ page 172

atio
om
n
c
3.2 Rules for cleanliness when working on

i
or
n thi
te
sd
a
fuel supply system or injection system

iv
o
pr
cum
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fo
When working on the fuel supply/injection system, carefully follow

en
ng
t.
yi Co
the “6 rules” below: t. Cop py
rig
gh ht
♦ Thoroughly clean all joints and surrounding areas before dis‐ yri
p by
o Vo
mantling.
c by lksw
cted agen
Prote AG.
♦ 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 parts that
have been kept unpackaged (for example in toolboxes).
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
3. Repair notes 7
Caddy 2011 ➤
♦ Also ensure that no diesel fuel comes into contact with the
coolant hoses. Should this occur, the hoses must be cleaned
immediately. Damaged hoses must be renewed.
3.3 Rules for cleanliness during work on fuel

system
Caution
If a mechanical fault is found on the turbocharger, e.g. a de‐

stroyed compressor impeller, just renewing the turbocharger is
not enough. To avoid subsequent damage, the following work
must be carried out:
♦ Check air filter housing, air filter element andageintake
n AG. Vohoses
lkswagen AG
does
for soiling. yV
olksw not
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ed ran
♦ Check the whole charge air pathho
risand charge air cooler for tee
foreign objects. s aut or
ac
s
If foreign objects are found in the charge air system, the charg‐
ce
le
un
pt
ed air routing must be cleaned and the charge air cooler must
an
d
itte
y li
be renewed, if necessary.
erm
ab
ility
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wit
is n
When working on the turbocharger, pay careful attention to the
h re
ole,
following rules for cleanliness:
spec
♦ Thoroughly clean all joints and surrounding areas before dis‐
t to the co
mantling.
♦ Place removed parts on a clean surface and cover them over.
rrectne
Use lint-free cloths only!
♦ If repair work cannot be performed immediately, cover new
ss
parts which have been removed from their packing.
o
cial p
♦ Install only clean parts; do not remove new parts from pack‐ f inform
mer
aging until immediately before installing. Do not use parts that

atio
m
have been kept unpackaged (for example in toolboxes).

o
n
c
i
or
♦ Transportation and protective packaging and sealing caps

thi
te
sd
a
must be removed only immediately before fitting.

iv
o
pr
cum
r
fo
♦ When making repairs, remove oil from connection and hose

en
ng
t.
ends.
yi Co
Cop py
t. rig
♦ When installing, does not use any fluid containing oil, silicone
gh ht
pyri by
or grease.
o Vo
by c lksw
cted agen
Prote AG.
♦ If system is open, do not work with compressed air. Do not
move the vehicle.
3.4 General repair notes for working on fuel

systems
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, initial fuel filling must
be carried out.
♦ If a fuel pump, fuel line (between fuel tank and fuel high-pres‐
sure pump) or fuel filter is removed or renewed
♦ Fuel system must be bled before starting engine for first time.
♦ If the high-pressure fuel pump is removed or renewed, the fuel
system must be bled before engine is started for the first time.

Caddy 2011 ➤
♦ Initial fuel filling procedure ⇒ page 277 .

• Clean tools and workbench etc. before working on injection
system.
• Thoroughly clean all joints and surrounding areas before dis‐
mantling.
• When removing components, aseal n Aall
G. Vopen
olkswaconnections
gen AG im‐
w ge does
mediately with suitable, clean
Vo lks protective caps. not
g by ua
ed ra
• Do not remove sealing ris caps from components until immedi‐ ntee
utho
ately prior to installation. Removed components should be or
sa ac
kept in new, sealable plastic bags (use the original new part
s
ce
e
packaging if possible).
nl
pt
du
an
itte
y li
• Before installation, check injectors and their surroundings vis‐
erm
ab
ually; they must be undamaged and free of lint. Ensure that
ility
ot p
the injector bore is clean.
wit
, is n
h re
• Only cleaning set - VAS 6811- may be used for cleaning the
hole
spec
sealing surface of the injector bore.
es, in part or in w
t to the co
• 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 instructions provided with the cleaning set - VAS
rrectness of i
6811- .
l purpos
• 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).
nf
ercia
or
• The following components and seals/O-rings must always be
m
m
atio
renewed when the injectors are removed and installed: “cop‐
om
n in
per seal”, “O-ring for injector bore”, “O-ring for injector return
or c
connection”, “injector return connection clip”

thi
te
sd
iva
o
r

rp
cu
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renewed when an injector is renewed: “copper seal”, “O-ring

f
en
ng
t.
yi
for injector shaft” and “O-ring for injector return connection”
Co
op py
“injector return clip” t. C rig
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pyri by
• Always fit new copper seals for the injectors. Check all new O-
co Vo
by lksw
cted
rings for damage before installing. O-rings must be moist when
agen
Prote AG.
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.
• Align high-pressure lines free from tension. First tighten all
unions hand-tight and then tighten to torque.
• Never attempt to reshape high-pressure fuel lines.
• When working on any parts of the high-pressure fuel system,
tools may only be used for loosening and tightening pipe un‐
ions. All other components must always be removed and
installed by hand without using tools or other equipment.
• Disassembling individual common rail components is not per‐
mitted.
• The components should be replaced as complete units if faul‐
ty.
• Never attempt to bleed the common rail system by loosening
high-pressure components after starting the engine.
• Do not carry out any installation work on common rail system
whilst engine is running.
• In particular, do not open or release high-pressure lines and
electrical connectors.
3. Repair notes 9
AG. Volkswagen AG d
agen oes
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Caddy 2011 ➤ by
Vol not
gu
d ara
4-cylinder diesel engine (2.0 l engine,
orise common rail) - Edition 09.2016 nte
h eo
aut ra
c
• New cable ties must be fitted in sthe same positions during in‐
s
ce
e
stallation as those which were undone or cut open during
nl
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removal.
itte
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erm
ab
• When the fuel system is open: do not work with compressed
ility
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air if this can be avoided. Try not to move the vehicle.
wit
, is n
h re
• Also ensure that no diesel fuel comes into contact with the hole
spec
coolant hoses. Should this occur, the hoses must be cleaned
es, in part or in w
immediately. Damaged hoses must be renewed.
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 ➤
10 – Removing and installing engine

1 Removing and installing engine
⇒ “1.1 Removing engine”, page 11
⇒ “1.2 Separating engine from gearbox”, page 23
⇒ “1.3 Separating engine from dual clutch gearbox”, page 25
⇒ “1.4 Securing engine on engine and gearbox support”,
page 27
⇒ “1.5 Installing engine”, page 28
1.1 Removing engine
Special tools and workshop

equipment required
♦ Lifting tackle - 3033- agen
AG. Volkswagen AG d
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♦ Hose clamps, up to 25 mm ed b y V gu
ara
- 3094- horis nte
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a
♦ Torque wrench ss c
(5 … 50 Nm) - V.A.G 1331-
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pt
du
an
itte
♦ Torque wrench (40 ... 200
y li
erm
ab
Nm) - V.A.G 1332-
ility
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♦ Stepladder - VAS 5085-
wit
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h re
hole
♦ Workshop hoist - VAS
spec
6100-
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
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for
en
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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.
1. Removing and installing engine 11

Caddy 2011 ➤
♦ Engine bung set - VAS 6122-
AG. Volkswagen AG d
agen oes
olksw not
♦ Drip tray for workshop hoist - VAS 6208- ed by
V gu
ara
ris nte
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aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
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h re
hole
spec
es, in part or in w
t to the co
rrectness of i
♦ Pliers for spring-type clips - VAS 6362-
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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rp
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fo
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t.
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Cop py
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♦ Tensioning straps - T10038- Prote AG.
12 Rep. gr.10 - Removing and installing engine

Caddy 2011 ➤
♦ Ratchet ring spanner - T10384-
♦ Transportation lock - T10404-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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Note
ce
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un
pt
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♦ Read out radio anti-theft code as the battery earth strap has
erm
ab
to be disconnected during the next work steps.
ility
ot p
wit
♦ The engine is removed forwards together with the gearbox.
is n
h re
ole,
♦ All cable ties that are opened or cut through when the engine spec
is removed must be renewed/replaced in the same position

t to the co
when the engine is installed.

rrectne
WARNING
s

s o
cial p

inform
itations:
mer
atio

om
restored.
c
i
or
n thi
e

t
sd
iva
nents.
pr
cum
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fo
en
ng
t.
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Cop py
Removing
t. rig
gh ht
pyri by
Vo
o
– Disconnect earth strap at battery with ignition switched off ⇒
c by lksw
cted agen
Electrical system; Rep. gr. 27 ; Disconnecting and connecting Prote AG.
battery.
– Remove air filter housing with air mass meter and connecting
pipe ⇒ page 341 .
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .

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byV ua
d ran
ir se tee
o
Caddy 2011 ➤ auth or
ac
ss
ce
e
nl
pt
du
an
– Remove battery tray. To do this, unscrew bolts -arrows-.
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
op
– Detach vacuum line -arrow- on brake servo. C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove fuel supply hose -2- and return hose -4-.
– Unscrew bolts -arrows-.

– Disconnect electrical connector -1- for coolant shortage indi‐
cator switch - F66- and push coolant expansion tank to side.
– Remove supplementary fuel pump - V393- ⇒ Fuel supply;
Rep. gr. 20 ; Supplementary fuel pump - V393- ; Removing
and installing Supplementary fuel pump - V393- .

Caddy 2011 ➤
– Unclip coolant hose bracket -1- by pushing to side.
– Loosen bolt -1-. n AG. Volkswagen AG do

lkswage es n
ot g
– Unscrew bolt -2- and nut -3-. d byV
o
ua
ran
ir se tee
– Take hose retainer -4- off fuel filter, place fuel
uth filter -7- aside
o
or
(fuel hoses -5- and -6- remain connected). ss
a ac
ce
e
nl
– Collect any escaping fuel.
pt
du
an
itte
y li
– If fitted, remove noise insulation ⇒ General body repairs, ex‐
erm
ab
terior; Rep. gr. 66 ; Body - front; Noise insulation .
ility
ot p
wit
, is n
– Drain coolant ⇒ page 207 .
h re
hole
spec
Vehicles with air conditioning system
es, in part or in w
t to the co
– Extract refrigerant from air conditioning system ⇒ Heating, air
conditioning system; Rep. gr. 87 .
rrectness of i
l purpos
nform
ercia
– Unscrew refrigerant lines -arrow- from lock carrier.

m
at
om
ion
Continued for all vehicles
c
in t
or
his
e
– Remove lock carrier ⇒ General body repairs, exterior; Rep.

at
do
riv
gr. 50 ; Body, front; Lock carrier .

p
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Unscrew bolt -arrow-, and place filler neck for windscreen

washer system reservoir to one side.
– Remove coolant expansion tank and place on engine.

Caddy 2011 ➤
– Pull off vacuum hoses -1- and -2- for charge air control.
– Disconnect connectors.
♦ -1- Exhaust gas temperature sender 3 - G495-

♦ -3- Lambda probe - G39-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Pull out wiring connector -1- for exhaust gas temperature
ss
sender 4 - G648- from bracket -2- behind battery, release and
ce
e
nl
pt
du
separate.
an
itte
y li
erm
ab
– Guide lines out of brackets on plenum chamber bulkhead and
ility
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on turbocharger.
wit
, is n
h re
– Remove plenum chamber bulkhead ⇒ General body repairs;
hole
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
spec
es, in part or in w
– Remove engine control unit from its bracket ⇒ page 343 .
t to the co
rrectness of i
l purpos
– Release connector for engine wiring harness -arrow- and pull

it off engine control unit. 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.

Caddy 2011 ➤
– Open catch -A- of passage in plenum chamber bulkhead and

pull top part out upwards. Remove engine control unit wiring
harness from cable duct.
– Unscrew bolt -arrow- (attached), unscrew intake hose -A-

clockwise out of its bracket and remove.
– Disconnect quick-release couplings for heat exchanger

-arrows- on plenum chamber bulkhead.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl
pt
– Unbolt positive cable -arrow- from starter at central electrics
du
an
itte
and lay cable on engine.

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.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
17
cted agen
Prote AG.
1. Removing and installing engine
Caddy 2011 ➤
– Detach connectors -1- and-2- from left longitudinal member of

vehicle. AG. Volkswagen n AG do
wage es n
– Remove engine control unit wiring harness olks
y V from cable duct.
ot g
b ua
ed ran
– Unbolt earth cable on gearbox. thoris tee
or
au ac
– Place engine wiring harness on engine.
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
Vehicles with dual clutch gearbox
t to the co
– Remove selector mechanism from gearbox ⇒ Rep. gr. 34 .
rrectness of i
– Release mechatronic unit connector -1- by turning, and pull off
connector.
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
Vehicles with manual gearbox

t.
yi Co
Cop py
– Remove selector mechanism from gearbox ⇒ 6-speed man‐
t. rig
gh ht
yri
ual gearbox; Rep. gr. 34 ; Selector mechanism . p by
co Vo
by lksw
cted agen
– Unscrew bolt -3-.
Prote AG.
– Remove bolts -arrows- and lay clutch slave cylinder aside. Do

not open hydraulic system.
– Guide clutch slave cylinder under strut -1-.

Caddy 2011 ➤

– Disconnect all connectors between starter, gearbox and body.
– Pull off connector -2- from exhaust gas pressure sensor 1 -
G450- .
AG. Volkswagen AG d
– Unscrew bolts -3- and -4-. 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
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Unclip exhaust gas pressure sensor 1 - G450- lines with brack‐
et -1- from upper toothed belt guard.
ss o
– Move back exhaust gas pressure sensor 1 - G450- with lines.
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
– Unscrew bolt -1- from exhaust gas pressure sensor 1 - G450- cted agen
Prote AG.
bracket.
– Remove exhaust gas pressure sensor 1 - G450- bracket.

Caddy 2011 ➤
– Undo bolt -arrow- in upper bracket of particulate filter. Loosen

bolt of bracket on cylinder head one turn.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
– Detach connector from oil level and oil temperature sender -
ce
e
nl
pt
du
G266- .
an
itte
y li
erm
ab
All-wheel drive vehicles
ility
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– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
wit
, is n
39 ; Propshaft; Removing and installing propshaft .
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Remove heat shield above right drive shaft -1-.
nf
ercia
or
Vehicles with front-wheel drive
m
m
atio
om
n in
or c
thi
te
sd
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– Remove right drive shaft cover.

Vehicles with manual gearbox
– Remove drive shafts from gearbox ⇒ Running gear, axles,
steering; Rep. gr. 40 ; Drive shafts; 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
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– Remove securing clamp -1- between particulate filter and tur‐

ot p
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bocharger.
, is n
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es, in part or in w
t to the co
rrectness of i
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Caddy 2011 ➤
Volkswagen AG
– Loosen securing nuts above particulate filter bracket -1- usingswagen AG. does
ratchet wrench, 13 mm - T10384- . by
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– Unscrew securing nuts -2- for particulate filter bracket
ho on
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– Push particulate filter to side and secure to plenum chamber
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bulkhead with suitable means.
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Note
wit
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Check that all hose and line connections between engine, gear‐ es, in part or in w
box and body have been detached.
t to the co
rrectness of i
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ercia
orm
m
– Attach lifting tackle - 3033- as follows and take up weight of
atio
m
»engine/gearbox assembly« in installation position using

o
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or c
workshop crane - VAS 6100- .
thi
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Vibration damper end:
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Flywheel end: t. C rig
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• Position 8.
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– Unscrew securing bolts -arrows- of assembly mounting at en‐

gine.
– Unscrew securing bolts -arrows- of assembly mounting at

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

avoid damage to body.
– Lower »engine/gearbox assembly« slightly and remove for‐

wards.

Caddy 2011 ➤
– Check needle bearing -arrow- in crankshaft. If it is damaged

or has turned blue, it must be renewed ⇒ page 93 .
– If it is not damaged, grease it lightly with high-temperature
grease as per ⇒ Electronic Parts Catalogue (ETKA) .
Secure engine to engine and gearbox support - VAS 6095A- to
carry out repairs ⇒ page 27 .
1.2 Separating engine from gearbox

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

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spec
t to the co
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cial p
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♦ Lifting tackle - T40013-

form
mer
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Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- .

Caddy 2011 ➤
– Unscrew bolts -arrows- and remove gearbox support.
– Unscrew bolts -1- and -2- and remove starter from gearbox.
Vehicles with all-wheel drive:

olkswagen AG
en AG. V
– Unscrew bolts -arrows 2, o3-
lksfor
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Ignore -arrows 1-.

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Continued for all vehicles:

– Attach lifting tackle - T40013- to gearbox and close lock.
rrectness of i
– Attach workshop hoist - VAS 6100- with hooks - 10 - 222 A /

l purpos
2- to lifting tackle.
nf
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orm
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Prote AG.

Caddy 2011 ➤
– Unscrew bolts -1, 2, 5, 6, 7, 8- from gearbox to engine con‐

nection.
Note
Ignore -items 3, 4- and -A-.
– Pull gearbox off engine.
1.3 Separating engine from dual clutch

gearbox
♦ Adapter - 10 - 222 A /20-
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♦ Hook of -2024 A /1- lifting tackle - 2024 A-

spec
es, in part or in w
t to the co
rrectness of i
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nform
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at
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ion
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or
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um
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Caddy 2011 ➤
Procedure
• Engine/gearbox assembly removed and attached to engine
bracket - T10012- . en AG. V
olkswagen AG
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– Remove coolant hoses y V from gear oil cooler, loosen hose
ot g clips
ua
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-arrows- for this.rise ran
te
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itte
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ility
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– Attach hook of lifting tackle - 2024 A- to gearbox lifting eye and
es, in part or in w
secure with pin -arrow-.
t to the co
– Attach workshop hoist - VAS 6100- to lifting tackle using hook
- 10 - 222 A /20- .
rrectness of i
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nform
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– Free wiring harnesses -arrows- and electrical connector -1- at

bracket.
– Unscrew bolts -1- and -2- and remove starter from gearbox.

Caddy 2011 ➤
– Unscrew bolts -1 to 9- securing gearbox to engine.

– Pull gearbox off engine.
AG. Volkswagen AG d
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1.4 Securing engine on engine and gearbox
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♦ Lifting tackle - 3033-
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♦ Engine and gearbox support - VAS 6095A-
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Caddy 2011 ➤
Procedure
– Unbolt gearbox.
– Attach lifting tackle - 3033- as follows and lift slightly with
workshop hoist - VAS 6100- .
Flywheel end: position 4.
Vibration damper end: position 8.
– Secure engine on engine and gearbox support - VAS 6095A- .
1.5 Installing engine

Install in reverse order of removal, observing the following:
WARNING
It is essential to refer to TPI 2030906/1 before installing engine.

Not adhering to these instructions can leadagto damage
en AG. Volkswto
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cylinder head or cylinder head cover. Volksw not
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♦ Renew bolts tightened through an additional specified angle.

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♦ Renew self-locking nuts and bolts as well as gaskets, seals

ot
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and O-rings.
h re
hole
spec
♦ Hose unions and air intake pipes and hoses must be free of
es, in part or in w
oil and grease before installation.

t to the co
♦ Secure all hose connections with the hose clips corresponding

to original equipment ⇒ ETKA (Electronic parts catalogue) .
rrectness of i
♦ Attach cable ties in all the same places when installing.

l purpos
nform
mercia
a
com
tion in
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Cop py
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Prote
28
AG.
Rep. gr.10 - Removing and installing engine
Caddy 2011 ➤
– If there are no dowel sleeves -A- in the cylinder block for cen‐
tring the engine and gearbox, insert new dowel sleeves.
– Make sure that intermediate plate is hooked into sealing flange

and pushed onto dowel sleeves -arrows-. n AG. Volkswagen AG
wage does
Vehicles with manual gearbox: olks not
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– If clutch release bearing thisor worn, renew it ⇒ Rep. gr. 30 ; eo
Clutch mechanism . ss au ra
c
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– Lightly grease gearbox input shaft splines with grease for

nl
pt
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clutch plate splines ⇒ ETKA (Electronic Parts Catalogue) .
itte
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erm
ab
– Check centring of clutch plate.
ility
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– Install clutch slave cylinder ⇒ Manual gearbox; Rep. gr. 30 ;
h re
Clutch mechanism .
hole
spec
– Install gearbox selector mechanism and adjust if necessary ⇒
es, in part or in w
t to the co
Manual gearbox; Rep. gr. 34 ; Clutch mechanism .
– Install cables with cable support bracket ⇒ Manual gearbox;
Rep. gr. 34 ; Clutch mechanism .
rrectness of i
– Install hydraulic line for hydraulic clutch ⇒ 6-speed manual
l purpos
gearbox; Rep. gr. 30 .

– Install gearbox shift mechanism and adjust if necessary ⇒ 6-
nf
ercia
speed manual gearbox; Rep. gr. 34 .

rm
m
atio
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Vehicles with dual clutch gearbox:

o
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or c
thi
Repair work on clutch ⇒ 6-speed dual clutch gearbox; Rep. gr.

te
sd
a
30 .
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– Install gearbox selector lever cable and adjust if necessary ⇒

en
ng
t.
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6-speed dual clutch gearbox; Rep. gr. 34 .
Co
Cop py
t. rig
gh ht
yri by
– Check needle bearing -arrow- in crankshaft. If it is damaged cop Vo
by lksw
or has turned blue, it must be renewed ⇒ page 93 .
cted agen
Prote AG.
– If it is not damaged, lightly grease with high-temperature

grease ⇒ ETKA (Electronic Parts Catalogue) .
– 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

swa
g35
en A.G. V
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Note utho eo
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♦ After working on particulate filter, ensure it is installed free of

nl
pt
du
stress.
an
itte
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erm
ab
♦ Renew self-locking nuts, seals, gaskets and securing clamps.
ility
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wit
, is n
h re
hole
Caution
spec
es, in part or in w
t to the co
Avoid damage of flexible joint behind particulate filter. When
removing and installing:
♦ Do not allow the decoupling element to kink by more than
rrectness of i
10°. Secure with transportation lock - T10404- .
l purpos
♦ Install decoupling element so that it is not under tension.
nform
♦ Do not damage wire mesh on decoupling element.
mercia
at
om
ion
– Install particulate filter ⇒ page 354 .
c
in t
or
his
te
– Bolt drive shafts to gearbox ⇒ Running gear, axles, steering;

a
do
riv
Rep. gr. 40 ; Drive shafts; Removing and installing drive

p
cum
or
shafts .
f
en
ng
t.
yi Co
op
– Install heat shield for right drive shaft ⇒ Gearbox; Rep. gr.
C py
t. rig
gh
34 ; Removing and installing gearbox .
ht
pyri by
Vo
co lksw
by
– Install starter ⇒ Starter, current supply, CCS; Rep. gr. 27 ; cted agen
Prote AG.
Starter; Removing and installing starter .
– Installing radiator ⇒ page 225 .
– Connect coolant hoses with plug-in connector to heat ex‐
changer for heater.
– Install exhaust gas pressure sensor 1 - G450-
– Install washer fluid reservoir filler pipe with filler neck.
– Electrical connections and routing ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
– Install battery and battery carrier ⇒ Electrical system; Rep. gr.
27 ; Battery .

Caddy 2011 ➤
– When mounting intake connecting pipe on turbocharger, it

must be ensured that intake connecting pipe is correctly seat‐
ed on the bolt of the turbocharger. -arrow-.
– Install air filter housing ⇒ page 341 .
– Check oil level ⇒ page 172 .
– Install lock carrier ⇒ General body repairs, exterior; Rep. gr.
50 ; Body, front; Lock carrier .
– Secure refrigerant lines free of stress to air conditioner com‐
pressor and to condenser ⇒ Heating, air conditioning; Rep.
gr. 87 .
– Charge air conditioner ⇒ Heating, air conditioning; Rep. gr.
87 .
– Install battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Removing and installing battery .
– Observe notes after connecting battery ⇒ Electrical system; n AG. Volkswagen AG do
Rep. gr. 27 ; Disconnecting and reconnecting battery . olks
wage es n
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yV t gu
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rise nte
Caution tho eo
au ra
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ss
Danger of destroying control units through excessive voltage.
ce
e
nl
pt
du
an
itte
♦ Never use battery charging equipment for boost starting.
y li
erm
ab
ility
ot p
wit
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– Add coolant ⇒ page 207 .
h re
hole
spec
– Fill fuel system ⇒ page 277 .
es, in part or in w
t to the co
– Read event memories of all control units.
– 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, if removed ⇒ General body repairs,
nform
ercia
exterior; Rep. gr. 66 ; Body, front; Noise insulation .

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

his
ate
do
priv
♦ ⇒ “2.1 Assembly overview - particulate filter”, page 351

cum
for
en
ng
t.
♦ ⇒ “2.2 Assembly overview - catalytic converter”, page 353
yi Co
Cop py
t. rig
♦ ⇒ “8.1 Assembly overview - air filter housing”, page 340 gh ht
pyri by
Vo
o
by c lksw
♦ Propshaft; Assembly overview - propshaft ⇒ Rep. gr. 39 ; Prote
cted AG.
agen
Assembly overview - propshaft
♦ Lock carrier; Assembly overview - lock carrier ⇒ Rep. gr. 50 ;
Assembly overview - lock carrier
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.
gr. 66 ; Assembly overview - noise insulation
♦ Removing and installing gearbox; Specified torques for gear‐
box ⇒ Rep. gr. 34 ; Removing and installing gearbox; Speci‐
fied torques for gearbox .

Caddy 2011 ➤
2 Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 32
⇒ “2.2 Adjusting assembly mountings”, page 35
⇒ “2.3 Removing and installing motor mounting”, page 41
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gen AG n AG d
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2.1 Assembly overview
db
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- assembly mount‐
not
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Adjusting assembly mountings
s ⇒ page 35
ce
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1 - Centre hex stud
erm
ab
ility
ot p
❑ Renew after removal
wit
is n
❑ Observe specified tor‐
h re
ole,
que and tightening se‐
spec
quence ⇒ page 34
t to the co
2 - Engine support
❑ Removing and installing
⇒ page 61
rrectne
3 - Bolt
ss
o
cial p
f in
❑ Specified torque and
form
mer
tightening sequence
atio
⇒ page 34
om
n
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4 - Bolt
thi
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❑ 40 Nm +90°
fo
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t.
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5 - Cross-piece ht. Cop py
rig
rig ht
6 - Bolt py by
co Vo
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Prote AG.
❑ 20 Nm +90°
7 - Bolt
❑ 20 Nm +90°
8 - Bolt
❑ 60 Nm + 90°
9 - Engine mounting (hydraulic
mounting)
❑ With support arm
Caution
Damage
♦ to the mem‐
brane will result in loss of
hydraulic fluid and thus
impair functionality.
❑ The membrane can be found on the underside of the engine mounting ⇒ page 33 .
❑ In the event of damage to the membrane, renew engine mounting.
10 - Pendulum support
❑ Note tightening sequence ⇒ page 34

Caddy 2011 ➤
11 - Bolt
❑ Observe specified sequence when removing and installing ⇒ page 34
❑ Observe specified torque ⇒ page 34
12 - Bolt
13 - Bolt
14 - Bolt
❑ 60 Nm +90°
15 - Bolt
❑ 40 Nm +90°
16 - Gearbox mounting
❑ With support arm
17 - Gearbox support
18 - Bolt
❑ Specified torque ⇒ Rep. gr. 34
olkswagen AG
en AG. V
19 - Bolt olks
wag does
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❑ Specified torque ⇒ Rep.isegr.
d 34
b ara
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20 - Support aut ra
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21 - Bolt
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❑ Specified torque ⇒ Rep. gr. 34

itte
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Membrane of engine mounting

h re
ole,
spec
The membrane -arrow- must not be damaged.

t to the co
– If membrane is damaged, renew engine mounting

⇒ page 41 .
rrectness o
cial p
f inform
mer
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om
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c
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t.
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Cop py
t. rig
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Vo
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by
cted agen
Prote AG.
2. Assembly mountings 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
For these and all other gearboxes, class 10.9 bolts must be
used.
If there is no Heli-Coil insert in the 02Q gearbox, use class 8.8
bolts and the corresponding torque setting.
AG. Volkswagen AG d
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Tighten only if pendulum support is bolted d bto gearbox.
y gu
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Always renew after removing. auth
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Specified torque
ce
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itte
Component Specified torque
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erm
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ility
Bolt A: M10 x 35, property class 40 Nm +90°
ot p
8.8
wit
is n
h re
ole,
Bolt A: M10 x 35, property class 50 Nm +90°
spec
10.9
t to the co
Bolt B: M10 x 75, property class 40 Nm +90°
8.8
Bolt B: M10 x 75, property class 50 Nm +90°
rrectne
10.9
Bolt C: M14 x 1.5 x 70 100 Nm +90°
ss o
cial p
Pendulum support - tightening sequence f inform

mer
atio
Removing
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or
– First unscrew bolt -1-.

thi
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sd
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– Then unscrew bolts -2- and -3-.

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fo
Installing
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t.
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– First screw in bolts -2- and -3-. t. C rig
gh ht
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– Then screw in bolt -1-.
co Vo
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cted agen
Prote AG.
Engine bracket - specified torques and installation sequence
Note
Renew bolts for engine bracket.
– Tighten bolts in 3 stages in the sequence shown:

Stage Bolts Specified torque/turning further angle
1 -1 … 3- 7 Nm
2 -1 … 3- 40 Nm
3 -1 … 3- Turn 180° further

Caddy 2011 ➤
2.2 Adjusting assembly mountings

♦ Support - 10-222 A-
AG. Volkswagen AG d
agen oes
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♦ Hooks - 10-222A/2-
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
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♦ Adapter - 10 - 222 A /3-

en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
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cted agen
Prote AG.
♦ Adapter - 10-222A/16-
lkswage es n
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Caddy 2011 ➤ tho tee
or
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ss
a
common rail) - Edition 09.2016 ac
ce
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pt
♦ Adapter - 10-222A/ 30-
an
d
itte
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ab
pe
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
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nform
ercia
♦ Torque wrench (5 … 50 Nm) - V.A.G 1331-

m
a
com
tion in
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te o
thi
s
iva
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cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
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cted agen
Prote AG.
♦ Pliers for spring-type clips - VAS 6362-
At a later point, support bracket - 10-222 A- will be put onto lon‐

gitudinal members with adapters - 10 - 222 A/30- .

Caddy 2011 ➤
• To prevent damage to edges of wings, cover lower areas of

both adapters - 10 - 222 A/30- with woven adhesive tape
-arrow- ⇒ Electronic parts catalogue (ETKA, chemical sub‐
stances) .
Procedure
WARNING
When doing any repair work, especially in the engine compart‐

ment, pay attention to the following due to the cramped condi‐
tions:
restored.
nents.
– Remove air filter housing ⇒ page 341 .
– Loosen hose clip -4- and remove air hose.
Caution
To prevent damage to the electronic components when dis‐

connecting the battery : lksw AG. Vo agen AG
agen does
♦ Comply with precautions when disconnecting
Vol
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– Disconnect earth wire -arrow- from battery with ignition switch‐

ility
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ed off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and

wit
is n
reconnecting battery .
h re
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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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Caddy 2011 ➤
– Remove battery and battery tray -arrows-.

– Remove supplementary fuel pump - V393- The fuel lines re‐
main connected ⇒ Fuel supply; Rep. gr. 20 ; Supplementary
fuel pump - V393- ; Removing and installing Supplementary
fuel pump - V393- .
Note
For reasons of clarity, diagram shows installation position with

fuel filter removed.
lkswage es n
o ot g
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ed ran
– Unscrew bolt -1-. horis tee
ut or
a ac
– Push washer fluid reservoir filler pipe with filler neckss -2- to side.
ce
le
un
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itte
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erm
ab
ility
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wit
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spec
t to the co
rrectne
ss
o
cial p
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inform
mer
atio
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n
c
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or
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iva
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pr
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fo
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by
cted agen
– Unclip coolant hose bracket -1- by pushing to side. Prote AG.


Caddy 2011 ➤
AG. Volkswagen AG d
– Loosen bolt -1-. ksw
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not
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– Unscrew bolt -2- and nut -3-. ise
d b ara
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– Take hose retainer -4- off fuel filter, place
s aut
fuel filter -7- aside ra
c
(fuel hoses -5- and -6- remain connected).
s
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nl
pt
du
– Remove expanders from top side of wing on left and right.
an
itte
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es, in part or in w
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nform
mercia
at
– Set up support bracket - 10-222A- together with adapters -
om
io
10-222A/30- , adapter - 10-222A/3- and adapter - 10-222A/16-
n
c
in t
r
behind gas strut for bonnet.

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ate
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– Attach additional hook - 10 - 222 A /2- .

– Then, attach additional hook - 10 - 222 A /2- to adapter - 10 -
222 A /16- .
– Take up weight of engine/gearbox assembly by means of
spindles.
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- .
Caddy 2011 ➤
– Renew engine mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
– First screw bolts in loosely.
– Renew gearbox mounting bolts -arrows- in succession (if not

already carried out) and screw in hand-tight.
– First screw bolts in loosely. AG. Volkswagen AG d
agen oes
lksw not
Engine mounting d byV
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spec
– Using an assembly lever between engine bracket and support
es, in part or in w
arm -1-, adjust position of engine until the specifications listed
t to the co
below are obtained:
• There must be a distance of -a- = 13.5 mm between engine
rrectness of i
support -2- and right longitudinal member.
• The side of the engine support casting -2- must be aligned
l purpos
parallel to the support arm -1- (dimension -x- must be identical

on both sides).
nform
mercia
a
com
t
Note
ion in
r
te o
thi
Distance -a- = 13.5 mm can also be checked with a rod of suitable
s
iva
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size, or similar.
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– Tighten bolts for engine mounting.
Co
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Prote AG.

Caddy 2011 ➤
Gearbox mounting
– Ensure that edges of support arm (on gearbox side) -1- and
gearbox mounting -2- are parallel.
• Dimension -x- must be identical on both sides of mounting.
– Tighten bolts for assembly mounting.
Further installation is carried out in the reverse sequence. When
doing this, observe the following:
• Ensure that fuel lines are tight.
• Do not interchange supply line and return line (return line blue
or with blue marking, supply line black).
– Observe notes after connecting battery ⇒ Electrical system;
Rep. gr. 27 ; Disconnecting and reconnecting battery .
Torque settings
♦ ⇒ “8.1 Assembly overview - air filter housing”, page 340
2.3 Removing and installing motor mounting

Special tools and workshop equipment required agen
AG. Volkswagen AG d
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♦ Hose clip pliers - VAS 6362- d by V gu
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♦ Support - 10 - 222 A-
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Caddy 2011 ➤
♦ Hooks - 10-222A/2-
♦ Adapter - 10 - 222 A /3-
AG. Volkswagen AG d
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♦ Adapter - 10-222A/16- orise nte
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♦ Adapter - 10-222A/ 30-

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or c
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Vo
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by c lksw
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Prote AG.

Caddy 2011 ➤

stances) .
Removing
lkswage es n
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ir se tee
tho
u or
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ss
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nl
pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia
– Push washer fluid reservoir filler pipe with filler neck -2- to side.
m
at
om
ion
c
in t
or
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ate
do
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cum
for
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t.
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Cop py
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by
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Prote AG.
Caddy 2011 ➤

AG. Volkswagen AG d
agen oes
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Loosen bolt -1-.

m
– Unscrew bolt -2- and nut -3-. a

com
tion in
– Take hose retainer -4- off fuel filter, place fuel filter -7- aside
r
te o
thi

s
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cum

fo
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t.
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Cop py
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rig ht
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cted agen
Prote AG.

Caddy 2011 ➤
– Set up support bracket - 10-222A- together with adapters -

10-222A/30- , adapter - 10-222A/3- and adapter - 10-222A/16-
behind gas strut for bonnet.

222 A /16- .
– Take up weight of engine/gearbox assembly by means of
spindles.
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.
AG. Volkswagen AG d
agen oes
olksw not
– Unscrew bolts -1- and -2- and remove connecting
ed byV bracket. gu
ara
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o
– Unscrew bolts -3 … 6- and remove engine
aut
h mounting. eo
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Installing
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an
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pe
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Caution
ot
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hole
The tightening sequence and specified torques for the engine

spec
bracket securing bolts must be strictly adhered to.

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
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t.
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Cop py
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rig ht
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45
cted agen
Prote AG.
2. Assembly mountings
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.
AG. Volkswagen AG d
– Insert bolts -4- and -5- and then tighten them. agen oes
olksw not
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Further assembly is basically a reverse of theoridismantling
se se‐ nte
quence. When doing this, observe the following:
aut
h eo
ra
ss c
– Adjusting assembly mountings ⇒ page 35 .
ce
e
nl
pt
du
an
Torque settings
itte
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erm
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es, in part or in w
t to the co
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l purpos
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mercia
at
om
ion
c
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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
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rig ht
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Prote AG.

Caddy 2011 ➤
wage
3 Motor cover
lks es n
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⇒ “3.1 Removinguth and installing engine cover”, page 47
o tee
or
a ac
ss
3.1 Removing and installing engine cover
ce
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nl
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an
Removing
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ility
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Caution
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hole
The engine cover retainer on the cylinder head cover can break
spec
es, in part or in w
if not removed correctly. Always remove the engine cover pan‐
t to the co
el according to the following instructions.
Before removing engine cover panel, unclip any hoses or lines
from the cover.
rrectness of i
l purpos
– Grasp engine cover panel in areas marked by -arrows- and

pull upwards out of ball heads -1-. To do this, grip as far as
nform
ercia
possible beneath engine cover panel.

m
at
om
i
Installing
on
c
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or
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ate
Caution
do
priv
cum
for
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g
Before installing engine cover panel, make sure that securing

n
t.
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op
elements (ball sockets) are positioned correctly. Reset to cor‐ C py
t. rig
rect position if necessary. Otherwise the engine cover panel
gh ht
yri by
will be damaged.
cop Vo
by lksw
cted agen
Prote AG.
– If necessary, press ball sockets of engine cover panel into

correct position.
– Position engine cover panel on securing points and press cor‐
ners into fasteners.
3. Motor cover 47
Caddy 2011 ➤
13 – Crankshaft group
1 Cylinder block (pulley end)
⇒ “1.1 Assembly overview - crankcase”, page 48
⇒ “1.2 Assembly overview - ancillary bracket”, page 50
⇒ “1.3 Assembly overview - sealing flange, belt pulley end”, page
50
⇒ “1.4 Assembly overview - poly V-belt drive with air conditioning
compressor”, page 52
⇒ “1.5 Assembly overview - poly V-belt drive without air condi‐
tioner compressor”, page 53
⇒ “1.6 Removing and installing poly V-belt, vehicles with air con‐
ditioner”, page 53
⇒ “1.7 Removing and installing tensioner for poly V-belt”,
page 55
⇒ “1.8 Removing and installing bracket for ancillaries”,
page 56
⇒ “1.9 Removing and installing
genvibration
AG. Volkswdamper”,
agen AG
d
page 60
wa oes
olks no
⇒ “1.10 Removing and
d b installing engine bracket”, page 61
yV t gu
ar
e an
ris tee
⇒ “1.11 Renewingtho crankshaft oil seal - belt pulley end”, or
au
page 67 ss ac
ce
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un
⇒ “1.12 Removing and installing sealing flange on pulley end”,

pt
an
d
page 69
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1.1 Assembly overview - crankcase

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Note
es, in part or in w
t to the co
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
rrectness of i
thoroughly and renew the engine oil cooler in order to prevent

l purpos
subsequent damage.
nform
mercia
a
com
tion in
r
te o
thi
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iva
do
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cum
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Cop py
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Prote AG.
48 Rep. gr.13 - Crankshaft group

Caddy 2011 ➤
1 - Cylinder block
❑ Removing and installing AG. Volkswagen AG d
sealing flange and fly‐ agen oes
olksw not
V
wheel ⇒ page 73 . d by gu
ara
rise nte
❑ Removing and installing utho eo
ra
crankshaft ss a c
⇒ page 91 .
ce
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un
pt
❑ Assembly overview -
an
d
itte
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pistons and conrods
rm
ab
⇒ page 83 . pe
ility
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2 - Guide tube
h re
hole
❑ Renew O-ring after
spec
each removal
es, in part or in w
t to the co
3 - Clip
4 - Seals
rrectness of i
l purpos
5 - Oil filter bracket

❑ Assembly overview
nform
ercia
⇒ page 174
m
a
6 - Bolt
com
tion in
r
te o
thi
s
iva
❑ First, fit upper left and
do
r
rp
c
lower right bolts in
um
fo
place. Then, tighten all 4
en
ng
t.
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bolts alternately in diag‐
Co
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onal sequence
t. rig
gh ht
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⇒ page 50 . p by
co Vo
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cted
❑ 14 Nm +180°
agen
Prote AG.
7 - Bolt
❑ 13 Nm
8 - Thermostat (4/2-way valve)
❑ Thermostat is firmly in‐
stalled in valve.
❑ Can only be renewed as a complete item
❑ Removing and installing ⇒ page 218
9 - O-ring
10 - Lifting eye
11 - Bracket
12 - Bolt
Specified torque and tightening sequence ⇒ page 50
13 - Bolt
❑ 20 Nm
14 - Oil pan
❑ Clean sealing surface before fitting.
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
15 - Bolt
❑ 15 Nm
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:
AG. Volkswagen AG d
agen oes
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es, in part or in w
1.2 Assembly overview - ancillary bracket
t to the co
rrectness of i
Note
l purpos
Renew securing bolts for ancillary bracket.
nf
ercia
o
– Install bolts as follows:
rm
m
atio
m
♦ Bolts -1- and -2- M10 x 52.

o
n in
or c
♦ Bolts -3- and -4- M10 x 30.
thi
te
sd
iva
o
♦ Bolts -5- and -6- M10 x 60.
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en
ng

t.
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Cop py
t. rig
Stage Bolts Specified torque/turning further angle gh ht
pyri by
Vo
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1 -1 to 6- Screw in by hand as far as stop
lksw
cted agen
Prote AG.
2 -1 to 6- 40 Nm
3 -3- and -4- Turn 45° further
4 -1, 2, 5, 6- Turn 90° further
1.3 Assembly overview - sealing flange, belt pulley end

Caddy 2011 ➤
1 - Bolt
❑ Do not additionally oil or
grease thread and AG. Volkswagen AG d
shoulder. agen oes
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❑ Turning further ised b can be ara
nte
done in useveral
thor
stages. eo
a ra
❑ 180 Nm s +135°
s c
ce
e
nl
pt
2 - Crankshaft pulley
du
an
itte
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❑ With or without mark
erm
ab
(depending on version)
ility
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❑ Contact surface be‐
, is n
h re
tween toothed belt pul‐
hole
spec
ley and crankshaft must
es, in part or in w
be free from oil
t to the co
❑ Can only be fitted in one
position
rrectness of i
3 - Sealing ring
l purpos
WARNING
nform
ercia
A new seal is used from

07.12. The sealing lip of
m
at
om
this seal faces outwards,
ion
not inwards, as before.
c
in t
or
his
ate
do
riv

p
cum
or
grease the oil seal seal‐

f
en
ng
t.
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ing lip.
Co
Cop py
t. rig
❑ Before installing, re‐ yri
gh by
ht
move oil residue from
op Vo
by c lksw
crankshaft journal using
cted agen
Prote AG.
a clean cloth.
❑ Renewing ⇒ page 67
4 - Sealing flange
❑ Must seat on dowel pins.
❑ Insert with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
5 - Cylinder block
❑ Removing and installing crankshaft ⇒ page 91 .
❑ Dismantling and assembling pistons and conrods ⇒ page 83
6 - Dowel pin
7 - Bolt
❑ Specified torque and tightening sequence ⇒ page 52

Caddy 2011 ➤
Sealing flange at belt pulley end - Prescribed torque and tighten‐

ing sequence
– Tighten bolts for sealing flange at belt pulley end in the se‐
quence -1 … 10- in 3 stages as follows:
Stage Bolts Specified torque
2 -1 to 6- In diagonal sequence and in stages;
final torque 15 Nm
3 -7 to 10- Tighten to 15 Nm
1.4 Assembly overview - poly V-belt drive with air conditioning compressor
1 - Belt pulley and vibration

damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft pul‐
ley.
⇒ page 60
2 - Bolt
❑ 25 Nm
3 - Alternator
4 - Bracket
❑ Removing and installing n AG. Volkswagen AG do
⇒ page 56 olkswage es n
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5 - Bolt ir se
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❑ Renew after removal aut or
ac
ss
❑ 20 Nm +180°
ce
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pt
an
d
6 - Poly V-belt tensioning ele‐

itte
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ment
erm
ab
ility
ot p
7 - Air conditioner compressor

wit
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ole,
8 - Bolt
spec
❑ 45 Nm
t to the co
9 - Dowel sleeves
10 - Poly V-belt
rrectne
❑ Mark direction of rota‐

tion before removing
ss
❑ Check for wear

o
cial p
f in
❑ Do not kink
form
mer

atio
m
⇒ page 53
o
n
c
i
or
n thi
te
sd
iva
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cum
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ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
1.5 Assembly overview - poly V-belt drive without air conditioner compressor
1 - Vibration damper
❑ Installation position:
hole in vibration damper
must align over protru‐
sion on crankshaft pul‐
ley.
⇒ page 60
2 - Bolt
❑ 25 Nm
3 - Alternator
4 - Ancillary bracket
5 - Poly V-belt
❑ Cut through to remove
❑ Renew
❑ Do not lever off and re‐
use
AG. Volkswagen AG d
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erm
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ility
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1.6 Removing and installing poly V-belt, ve‐

wit
is n
hicles with air conditioner

h re
ole,
spec

t to the co
♦ Locking pin - T10060 A-

rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
cum
r
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
Removing
terior; Rep. gr. 66 ; Body - front;wNoise
agen insulation . AG doe
AG. Volkswagen
ks s no
Vol t gu
Vehicles with auxiliary heater
ed
by ara
is nte
or
– Unscrew bolt -2- fromau coolant pipe bracket -1- of
th auxiliary eo
ra
heater. ss c
ce
le
un
pt
an
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rm
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pe
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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
– Unscrew bolts -1- of coolant pipes for auxiliary heater -2- from
drive shaft heat shield.
nform
ercia

m
– Mark the direction of travel of the poly V-belt.
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Swing tensioning element in direction of arrow to relieve ten‐
sion on poly V-belt.
– Align the holes -arrows- with each other. Lock tensioning ele‐
ment using locking pin - T10060 A- .
– Remove poly V-belt.
Installing
Note
♦ Before installing poly V-belt, ensure that all ancillaries (alter‐

nator, air conditioner compressor) are properly secured.
♦ When fitting poly V-belt, check direction of belt rotation and
proper seating of belt in belt pulleys.

Caddy 2011 ➤
– Place 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.
lkswage es n
o ot g
byV ua
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1.7 Removing and installing tensioner for
utho tee
or
poly V-belt
a ac
ss
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e
nl
pt
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an
itte
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erm
ab
♦ Torque wrench (40 ... 200 Nm) - V.A.G 1332-
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
m
Removing
o
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or c
thi
– Remove poly V-belt ⇒ page 53 .

te
sd
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Notes on hose connections with screw-type clamps

rp
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⇒ page 241
f
en
ng
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– Loosen clamps -1 - and -2- and remove connecting hose. C py
t. rig
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– Remove radiator cowl with radiator fan - V7- and remove right cop Vo
by lksw
radiator fan - V35- ⇒ page 226 . cted agen
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 241
– Open clamp -2-.
– Make coolant hose -3- accessible and remove charge air pipe.
– Remove air conditioner compressor; do not detach refrigerant
lines on air conditioner compressor.
– Refrigerant circuit remains closed.
– Use suitable means to suspend air conditioner compressor on
body ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner
compressor; Removing and installing air conditioner compres‐
sor .
– Unscrew securing bolt -2-.

– Remove tensioning element for poly V-belt -1-.
Installing
Torque settings
♦ ⇒ “1.4 Assembly overview - poly V-belt drive with air condi‐
tioning compressor”, page 52
♦ ⇒ “3.1 Assembly overview - radiator/radiator fan”, page 224
AG. Volkswagen AG d
agen oes
olksw not
byV gu
1.8 Removing and installing bracket for an‐ d ara
ise nte
or eo
h
cillaries ss aut ra
c
ce
le

un
pt
an
d
itte
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♦ Support - 10 - 222 A-
rm
ab
pe
ility
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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
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fo
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Hooks - 10-222A/2-
lkswage es n
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un
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ab
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spec
♦ Adapter - 10 - 222 A /3-
t to the co
rrectness o
cial p
f inform
mer
atio
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n
c
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fo
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♦ Adapter - 10-222A/16-
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Adapter - 10-222A/ 30-

Caddy 2011 ➤

gitudinal members with adapters - 10 - 222 A/30- . n AG. Volkswagen AG
age does
ksw not
• To prevent damage to edges of wings, by cover lower areas of
Vol gu
ara
both adapters - 10 - 222 A/30- withrisewoven adhesive tape
d
nte
-arrow- ⇒ Electronic parts catalogue
aut
ho (ETKA, chemical sub‐ eo
ra
stances) . ss c
ce
le
un
Removing
pt
an
d
itte
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– Remove high-pressure pump ⇒ page 317 .
rm
ab
pe
ility
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
ot
wit
, is n
nator; Removing and installing alternator .
h re
hole
spec
Vehicles with air conditioning system
es, in part or in w
t to the co
WARNING
rrectness of i
The air conditioner refrigerant circuit must not be opened.
l purpos
– Unbolt air conditioner compressor from ancillary bracket, then nform

ercia
secure to lock carrier ⇒ Heating, air conditioning; Rep. gr. 87 ;

Air conditioner compressor; Removing and installing air con‐
m
a
com
ditioner compressor .
ion in
r
te o

thi
s
iva
do
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rp
cum
– Remove idler pulleys -1- and -2- and unscrew bolt for toothed
fo
en
g
belt guard -arrow-.

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

Caddy 2011 ➤
– Undo front bolt -1- of engine bracket.
– Unscrew bolts -6...1- and remove ancillary bracket.

Installing
wage es n
Install in reverse order of removal, observing
yV
olks the following: ot g
ua
d b ran
e
♦ Note any fitted sleeves in ancillary
horis
bracket and renew missing tee
ones if necessary. aut or
ac
ss
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le
♦ Renew all bolts to be tightened with torque angle.

un
pt
an
d
itte
♦ Tack engine bracket bolt before tightening ancillary bracket
y li
rm
ab
securing bolt.
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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– Tighten bolts in sequence -1…6- ⇒ page 50 .

nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Screw in and tighten front bolt -1- of engine bracket

⇒ page 61 .
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Alternator;
Removing and installing alternator .
– Install air conditioner compressor ⇒ Heating, air conditioning;
Rep. gr. 87 ; Air conditioner compressor; Removing and in‐
stalling air conditioner compressor .
– Installing high-pressure pump ⇒ page 317 .
– Install toothed belt and adjust valve timing ⇒ page 125 .
– Filling/bleeding high-pressure pump/fuel system
⇒ page 277 .
Torque settings
♦ ⇒ “2.1 Assembly overview - toothed belt drive”, page 123
♦ ⇒ “4.1 Assembly overview - high-pressure pump”, page 316
♦ ⇒ “1.2 Assembly overview - ancillary bracket”, page 50
♦ ⇒ “1.4 Assembly overview - poly V-belt drive with air condi‐
tioning compressor”, page 52 n AG. Volkswagen A ge G do
swa es n
♦ Alternator; Assembly overview - alternator ⇒by Alternator;
Vol
k
Rep. ot g
ua
gr. 27 ; Assembly overview - alternator rised ran
tee
tho or
s au ac
1.9 Removing and installing vibration damp‐ s
ce
e
nl
pt
er
du
an
itte
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erm
ab
ility
ot p
wit
♦ Torque wrench - V.A.G 1331-
, 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
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thi
e
Removing
t
sd
iva
o
r
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cu

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m
f
en
ng
t.
yi
– Remove cap for vibration damper.
Co
Cop py
ht. rig
– Unscrew bolts -1- while counterholding on centre bolt. rig ht
py by
co Vo
by lksw
– Remove vibration damper -2-. cted agen
Prote AG.

Caddy 2011 ➤
Installing
• Installation position: hole -arrow- in vibration damper must
align over protrusion on crankshaft pulley.
Torque settings
1.10 Removing and installing engine bracket

♦ Hose clamps, up to 25 mm - 3094-
♦ Hose clip pliers - VAS 6362-
lkswage es n
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tho
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un
pt
an
d
itte
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ab
ility
ot p
wit
is n
h re
♦ Support - 10 - 222 A-
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
cum
r
fo
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t.
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Cop py
t. rig
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pyri by
Vo
co lksw
by
61
cted agen
Prote AG.
1. Cylinder block (pulley end)
Caddy 2011 ➤
♦ Hooks - 10-222A/2-
♦ Adapter - 10 - 222 A /3-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
♦ Adapter - 10-222A/16- orise nte
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aut ra
ss c
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un
pt
an
d
itte
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erm
ab
ility
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is n
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ole,
spec
t to the co
rrectne
♦ Adapter - 10-222A/ 30-

ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤

stances) .
Removing
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
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ce
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nl
pt
du
an
– Remove fuel filter ⇒ Fuel supply; Rep. gr. 20 ; Removing and
itte
y li
installing fuel filter .
erm
ab
ility
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wit
, is n

h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nf
ercia

rm
m

atio
om
n in
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thi
te
sd
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f
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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 ➤
– Open quick-release fasteners -A- and -B- of fuel lines.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss
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pt
du
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itte
y li
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ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
– Unscrew bolt -2- and nut -3-.
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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t.
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Cop py
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Prote AG.

Caddy 2011 ➤
4-cylinder
gen AGdiesel
. Volkswengine
agen AG (2.0
d
l engine, common rail) - Edition 09.2016
wa oes
olks not
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– Set up support bracketise-d10-222A- together with adapters - aran
b
10-222A/30- , adapter ut
h - 10-222A/3- and adapter - 10-222A/16-
or tee
or
behind gas strut sfor
s a bonnet. ac
ce
le
un
pt
an
d
itte
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erm
ab
ility
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is n
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spec
t to the co
rrectness o
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f inform
mer
atio
om
n
c
i
or
n
thi
te
sd
va

i
o
pr
cum
222 A /16- .
r
fo
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ng
t.
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– Take up weight of engine/gearbox assembly by means of Cop py
spindles.
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note

– Unscrew bolts -1- and -2- and remove connecting bracket.

– Unscrew bolts -3 … 6- and remove engine mounting.

Caddy 2011 ➤
– Clamp off coolant hoses with hose clips, up to 25 mm - 3094-

and remove from coolant pipes; release hose clips -arrows-
for this.
– Disconnect electrical connector -3- on radiator outlet coolant
temperature sender - G83- .
– Remove nut -1- and bolt -2-, remove right coolant pipe.
WARNING
Make sure that no components or hoses are damaged, over‐

stretched or broken off when raising or lowering the engine via
support bracket - 10-222A- .
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-.
– Unscrew bolts of engine bracket in sequence -3…1-.

– Remove engine bracket out upwards.
AG. Volkswagen AG d
Installing agen oes
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Install in reverse order of removal, observing
orise the following: nte
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au ra
ss c
Caution
ce
e
nl
pt
du
an
itte
The tightening sequence and specified torques for the engine y li

erm
bracket securing bolts must always be followed. Otherwise the ab

ility
ot p
engine bracket can be stressed, causing it to break. wit

, is n
h re
hole
spec
– Insert engine bracket from above.

es, in part or in w
t to the co
Note
rrectness of i
The bolt -1- is accessible through an aperture in the wheel hous‐

l purpos
ing. Raise and lower engine using spindle of support bracket - 10

- 222 A- to remove or start bolts -2- and -3-.
nform
ercia
– Initially screw in new bolts hand-tight in the sequence -1...3-.

m
at
om
ion
c
in t
r
Tightening sequence for engine bracket

o
his
ate
do
riv
– Tighten bolts in the specified sequence to the prescribed tor‐

p
cum
or
que.
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not Caddy 2011 ➤
byV gu
aa
rised
4-cylinder diesel engine r(2.0nte l engine, common rail) - Edition 09.2016
ho eo
aut ra
– Fit engine assembly mounting in position. First, tighten bolts ss c
ce
e
-3- and -6- and then -1- and -2-.
nl
pt
du
an
itte
– Use the spindle to bring the engine bracket to rest on the as‐
y li
erm
ab
sembly mounting.
ility
ot p
wit
– Insert bolts -4- and -5- and then tighten them.
, is n
h re
hole
Add coolant ⇒ page 207 .
spec
es, in part or in w
Torque settings
t to the co
rrectness of i
♦ ⇒ Fuel supply; Rep. gr. 20 ; Fuel filter; Removing and instal‐
ling fuel filter
l purpos
1.11 Renewing crankshaft oil seal - belt pulley end
nform
mercia
at
om
i
on
c
equipment required
in t
or
his
ate
♦ Seal puller - 3203-
do
priv
cum
or
♦ Counterhold tool - 3415-

f
en
ng
t.
yi Co
op
♦ Assembly tool - T10053-
C py
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rig ht
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♦ Torque wrench co Vo
by lksw
(5 … 50 Nm) - V.A.G 1331-
cted agen
Prote AG.

Nm) - V.A.G 1332-

Caddy 2011 ➤
Removing
– Remove toothed belt ⇒ page 125 .
– Using counterhold tool - 3415- , loosen bolt -1- for crankshaft
pulley -2-.
– Remove crankshaft pulley -2-.
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
– To guide seal extractor - 3203- , screw centre bolt into crank‐
h re
hole
shaft as far as stop by hand.
spec
es, in part or in w
– Unscrew inner part of oil seal extractor 2 turns (approx. 3 mm)
t to the co
from the outer part and lock in position with the knurled screw.
– Oil threaded head of seal extractor.
rrectness of i
– Screw oil seal extractor forcibly as far as possible into oil seal.
l purpos
– Loosen knurled screw and turn inner part against crankshaft

until the oil seal is pulled out.
nf
ercia
or
Installing
m
m
atio
m

o
n in
or c
thi
te
sd
iva
WARNING o
r
rp
cu
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m
f
en
ng
t.
A new seal is used from 07.12. The sealing lip of this seal faces
yi Co
op
outwards, not inwards, as before.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.
– Fit guide sleeve - T10053/1- onto crankshaft journal.

– Slide seal over guide sleeve - T10053/1- onto crankshaft jour‐
nal.

Caddy 2011 ➤
– Press oil seal in as far as stop with press sleeve - T10053- and
central bolt.
– Install crankshaft pulley.
– Install and tension toothed belt ⇒ page 125 .
Torque settings
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
1.12 Removing and installing sealing flange
du
an
itte
y li
on pulley end
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
Removing
– Using counterhold tool - 3415- , loosen bolt -1- for crankshaft
pulley -2-.
AG. Volkswagen AG d
– Unscrew bolt -1-. agen oes
olksw not
V gu
by ara
– Remove crankshaft pulley
rised -2-. nte
ho eo
ut
– Remove sump ⇒ page
ss a 166 . 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
– Unscrew bolts -1 … 10- and carefully remove sealing flange

from the glued joint.
l purpos
– Remove sealing flange. If necessary, loosen sealing flange

using light blows with a rubber headed hammer.
nf
ercia
orm
– Remove sealant residues from cylinder block with a flat scra‐

m
atio
m
per.
o
n in
or c
thi
te
sd
iva
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m
f
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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
– Remove sealant residue from sealing flange with a rotating cted agen
Prote AG.
plastic brush (wear protective goggles).
– Clean sealing surfaces. They must be free of oil and grease.

Caddy 2011 ➤
Installing
Use sealant as per ⇒ Electronic Parts Catalogue (ETKA) .
AG. Volkswagen AG d
agen oes
Note olksw not
byV gu
ara
ed
ris nte
Observe use-by date of sealant. aut
ho eo
ra
ss c
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e
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
nl
pt
du
an
3 mm).
itte
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erm
ab
ility
ot p
wit
Note
, is n
h re
hole
spec
♦ The sealing flange must be installed within 5 minutes of ap‐
es, in part or in w
plying the silicone sealant.
t to the co
♦ The sealant bead must be no thicker than 2…3 mm. Excess
sealant can find its way into the sump and block the strainer
rrectness of i
in the suction line and drip on the sealing surface of the crank‐
shaft seal.
l purpos
♦ Before applying sealant bead, cover sealing surface of oil seal

with a clean cloth.
nf
ercia
orm
m
atio
m
– Apply a thin bead of sealant at the edge of the joint between

o
n in
c
the cylinder block and the sump -arrows-.

or
thi
te
sd
iva
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.
– Apply silicone sealant bead as shown in the illustration to clean

sealing surface of sealing flange.

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 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 166 .
Install toothed belt and adjust the valve timing ⇒ page 125 .
Torque settings
♦ ⇒ “2.1 Assembly overview - toothed belt adrive”,
gen AG page 123n AG do
. Volkswage
w es n
olks ot g
♦ ⇒ “1.1 Assembly overview - sump/oil
ed
by pump”, page 164
V ua
ran
ris tee
ho
♦ ⇒ “1.3 Assembly overview a-utsealing flange, belt pulley end”, or
ac
page 50 ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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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 Cylinder block, gearbox end

⇒ “2.1 Assembly overview - cylinder block, gearbox end”,
page 73
⇒ “2.2 Removing and installing flywheel”, page 74
⇒ “2.3 Removing and installing sealing flange on gearbox side”,
page 75
2.1 Assembly overview - cylinder block, gearbox end
1 - Bolt
❑ 60 Nm +90°
2 - Dual-mass flywheel
⇒ page 74
❑ Offset holes make as‐
sembly possible in one
position only
3 - Sender wheel
❑ For engine speed send‐
er - G28-
⇒ page 75
4 - Engine speed sender -
G28-
⇒ page 376
5 - Bolt
❑ 5 Nm agen
AG. Volkswagen AG d
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olksw not
6 - Dowel pin ed by
V gu
ara
ris nte
7 - Intermediate plate aut
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ra
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❑ Must seat on dowel s
ce
le
pins.
un
pt
an
d
itte
❑ Do not damage or bend

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rm
ab
when assembling
pe
ility
⇒ page 74 .
ot
wit
, is n
h re
8 - Sealing flange with oil seal

hole
spec
❑ With sender wheel for

es, in part or in w
engine speed.
t to the co
❑ Renew complete only.

❑ Do not additionally oil or grease the oil seal sealing lip.
rrectness of i
❑ Before installing, remove oil residue from crankshaft journal using a clean cloth.
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❑ Use support sleeve supplied when installing.

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9 - Bolt
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2. Cylinder block, gearbox end
Caddy 2011 ➤
Installing intermediate plate

– Attach intermediate plate to sealing flange -arrow at top- and
push onto dowel sleeves -arrows at bottom-.
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Sealing flange on flywheel pulley end - specified torque and tight‐
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Stag Bolts Specified torque
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2 -1 to 6- diagonally in stages; final torque

15 Nm
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2.2 Removing and installing flywheel
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Caddy 2011 ➤
Removing
– Remove clutch ⇒ Rep. gr. 30 ; Removing and installing
clutch .
– Insert counterhold tool - 3067- into hole in cylinder block
-item B-.
– Unscrew flywheel bolts -1-.
Installing
Note
Flywheel with sender wheel can only be fitted in one position.
– Insert counterhold - 3067- in hole in cylinder block -item A-.

– Tighten flywheel bolts -1-.
Torque settings
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
73
2.3 Removing and installing sealing flange

on gearbox side
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♦ Tool insert 24 mm - V.A.G 1332/11-

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2. Cylinder block, gearbox end 75

Caddy 2011 ➤
♦ Depth gauge - VAS 6082-
♦ 3 bolts M6 x 35 mm
Removing
Note
For reasons of clarity, the work procedures are described with the
engine removed.
wage e
– Remove gearbox ⇒ Rep. gr. Vol 34 ; Removing and installingot gu
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by
gearbox; Removing gearbox
ris
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– Remove flywheel s⇒aupage 74 . ac
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– Remove intermediate plate -1- from dowel sleeves

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-arrows A-.
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– Guide intermediate plate -1- upwards.

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– While doing so, pull retaining lug -arrow B- of intermediate

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plate -1- out of recess behind sealing flange.

hole
spec
– Remove sump ⇒ page 166 .

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– Remove engine speed sender - G28- ⇒ page 376 .

rrectness of i
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– Unscrew bolts -arrows- for sealing flange -1-.

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Note
on
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The sealing flange -1- is pressed off crankshaft -3- together with
a
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the sender wheel -2-.

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Caddy 2011 ➤
– Screw three M6 x 35 bolts -arrows- into sealing flange -1-.

– Screw bolts -arrows- alternately into sealing flange, and no
more than 1/2 turn at a time.
– Remove sealing flange -1- together with sender wheel -2-.
Installing
Note
♦ The sealing flange with a PTFE seal is equipped with a sealing

lip support ring. This support ring serves as a fitting sleeve and
must not be removed prior to installation.
♦ The sender wheel -1- and sealing flange -2- must not be sep‐
arated or turned once they have been removed from the
packaging.
♦ The sender wheel -1- is held in its installation position on the
locating pin of the assembly tool - T10134- .
Set-up of assembly tool - T10134- :

A - Clamping surface
B - Nut
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D - Locating pin horis nte
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F - Guide pin for petrol engines (red knob)

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G - Guide pin for diesel engines (black knob)

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H - Knurled screws (qty. 3)

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Fitting sealing flange with sender wheel on assembly tool -

T10134- :
– Screw on nut -B- until just before it touches the clamping sur‐
rrectness of i
face -A- of the threaded spindle.

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Caddy 2011 ➤
– Clamp assembly device - T10134- at clamping surface -A- of

threaded spindle in a vice -1-.
– Push assembly housing -C- downwards until it rests against
nut -B-.
• Inner part of assembly tool and assembly housing must be at
same height
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– If fitted, remove securing clip -arrow-sefrom
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– Place sealing flange with front side facing down on a clean
level surface.
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– Push sealing lip support ring -1- downwards in
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-direction of arrow- until it rests against flat surface.
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• Upper edge of sealing lip support ring -1- and front edge of
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sealing flange -2- must align -arrows-
Prote AG.

Caddy 2011 ➤
– Place sealing flange -1- with front side facing downwards onto
assembly tool - T10134- so that locating pin -D- is seated in
hole -3- in sender wheel hole -2-.
• The sealing flange must rest flat against the assembly tool
– Screw knurled screws -H- into sealing flange -1-.

– Press sealing flange -1- and sealing lip support ring -2- against
surface of assembly tool - T10134- whilst tightening knurled
screws.
Note
♦ This prevents the locating pin from slipping out of the sender
wheel hole.
♦ When installing sealing flange, ensure that sender wheel re‐
mains fixed in assembly tool. agen
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• The crankshaft flange must be free of grease and oil

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– Screw on nut -B- until it reaches end of threaded spindle. wit

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– Press threaded spindle of assembly tool - T10134- in
hole
spec
-direction of arrow-, until nut -B- rests against assembly hous‐
es, in part or in w
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– Align flat side of assembly housing to sealing surface of cyl‐

inder block on sump side.
rrectness of i
Secure assembly tool - T10134- together with sealing flange -1-

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on crankshaft flange -2-:
– Screw bolts -E- into crankshaft flange (approx. 5 full turns) us‐
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ing a hexagon key.

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– Push guide pin for petrol engines (red knob) -F- into crankshaft
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4-cylinder diesel engined b(2.0 l engine, common rail) - Edition
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– To guide sealing flange au-1-, screw two M6 × 35 mm bolts -3- ra
c
ss
into cylinder block -2-.
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Bolting assembly tool - T10134- onto crankshaft flange:

– Push assembly housing -C- by hand in -direction of arrow- until
nf
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sealing lip support ring -1- rests against crankshaft flange
orm
-2-.
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– Make sure that guide pin for petrol engines (red knob) -F- is
or c
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properly seated in hole in crankshaft. This ensures that the
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sender wheel reaches its final installation position.

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– Tighten bolts of assembly tool by hand.
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– Screw nut -B- by hand onto threaded spindle until it rests C py
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tool - T10134- :
– Tighten nut -B- of assembly tool - T10134- to 35 Nm.

• Once nut has been tightened to 35 Nm, a small gap must still
be present between cylinder block and sealing flange -1-.
Checking sender wheel installation position on crankshaft:
– Screw on nut -B- until it reaches end of threaded spindle.

– Unscrew bolts -2- from cylinder block.
– Pull guide pin for petrol engines (red knob) -F- out of crank‐
shaft flange.
– Unscrew knurled screws -H- from sealing flange -1-.
– Unbolt assembly tool - T10134- from crankshaft flange, un‐
screwing hexagon socket head bolts -E- from crankshaft
flange.
– Remove sealing lip support ring.

Caddy 2011 ➤
– Position depth gauge - VAS 6082- on crankshaft flange -2-.

– Measure distance between crankshaft flange -2- and sender
wheel -1-.
– Measure distance -a- between crankshaft flange -2- and send‐

er wheel -1-.
• Specification: dimension -a- = 0.5 mm AG. Volkswagen AG d
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– If specification is not achieved, press sender wheel inisefurther.
d b ara
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– If specification is achieved, proceed with remaining
s aut work ra
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Re-pressing sender wheel:
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– Secure assembly tool - T10134- on crankshaft flange.
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spec
– Make sure that locating pin of assembly tool - T10134- is prop‐
t to the co
erly seated in sender wheel hole.
– Tighten bolts -E- by hand.
rrectne
– Push assembly tool - T10134- by hand against sealing flange
-1-.
ss
– Screw nut -B- by hand onto threaded spindle until it rests
o
cial p
f
against assembly tool - T10134- .
inform
mer
– Push guide pin for petrol engines (red knob) -F- into crankshaft
atio
m
flange.
o
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– Screw knurled screws -H- into sealing flange -1-.
thi
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– To guide sealing flange, screw two M6×35 mm bolts -2- into
pr
cum
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fo
cylinder block.
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Prote AG.

Caddy 2011 ➤
– Tighten nut -B- of assembly tool - T10134- to 40 Nm.

– Check sender wheel installation position on crankshaft again.
– If the specification is not achieved, tighten nut of assembly tool
- T10134- to 45 Nm.
– Check sender wheel installation position on crankshaft again.
– Tighten bolts for sealing flange ⇒ page 74 .
– Install flywheel ⇒ page 74 .
– Install gearbox ⇒ Rep. gr. 34 ; Removing and installing gear‐
box; Installing gearbox .
Torque settings
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a gen AG does
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox Volend”, page
ksw not
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♦ ⇒ “1.1 Assembly overview - sump/oil pump”,
au
th page 164 ra
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Caddy 2011 ➤
3 Pistons and conrods

⇒ “3.1 Assembly overview - pistons and conrods”, page 83
⇒ “3.2 Checking pistons and cylinder bores”, page 85
⇒ “3.3 Piston and cylinder dimensions”, page 86
⇒ “3.4 Measuring piston projection at TDC”, page 86
⇒ “3.5 Checking radial clearance of conrods”, page 88
⇒ “3.6 Separating new conrods”, page 89
⇒ “3.7 Removing and installing oil spray jets”, page 89
3.1 Assembly overview - pistons and conrods
1 - Piston rings
❑ Offset gaps by 120°
❑ Use piston ring pliers to
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❑ Top and centre:
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❑ Bottom: Oil scraper ring. pt

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❑ Checking ring gap
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⇒ page 85 .
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❑ Checking ring-to-groove
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clearance ⇒ page 85 .
hole
spec
2 - Piston
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❑ With combustion cham‐

ber.
❑ Mark installation posi‐
rrectness of i
tion and cylinder num‐

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❑ Arrow on piston crown
points to belt pulley end.
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❑ Install using piston ring

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❑ If piston skirt is cracked,

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❑ Installation position and

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allocation of piston to
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cylinder ⇒ page 84 .
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❑ Checking piston projec‐
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3 - Piston pin
❑ If difficult to remove,
heat piston to 60°C.
❑ Remove and install using drift - VW 222- .
4 - Retaining ring
5 - Connecting rod
❑ Mark cylinder allocation -A- with coloured pen.
❑ Installation position: Marking -B- faces towards pulley end.
❑ With industrially cracked conrod cap.
3. Pistons and conrods 83

Caddy 2011 ➤
6 - Bearing shell
❑ Note version: Upper bearing shell (towards piston) is made of a more wear resistant material. Identifi‐
cation: Black line on bearing surface in area of joint.
❑ Do not interchange used bearing shells.
❑ Insert bearing shells centrally.
❑ Ensure firm seating.
❑ Axial clearance, wear limit: 0.37 mm
❑ Check radial clearance with Plastigage; wear limit: 0.08 mm.
❑ Do not rotate crankshaft when checking radial clearance.
❑ Note installation position ⇒ page 85
7 - Cylinder block
❑ Checking cylinder bores ⇒ page 86 .
❑ Piston and cylinder dimensions ⇒ page 86 .
8 - Conrod bearing cap agen
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9 - Oil spray jet ut
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❑ For piston cooling
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10 - Bolt
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❑ Insert without sealant.
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❑ 25 Nm
h re
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spec
11 - Conrod bolt
es, in part or in w

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❑ Oil threads and contact surface

❑ Use old bolt for measuring radial clearance.
rrectness of i
❑ 30 Nm +90°
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Installation position and allocation of piston to cylinder

orm
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• If worn pistons are to be reinstalled, mark their allocation to

om
the cylinder on the piston crown. Only use paint for this.
n in
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• Arrow on piston crown points to pulley end -arrow-.

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Caddy 2011 ➤
Installation position of bearing shells in conrods

– Centre bearing shells on conrod and on conrod bearing cap.
• Dimension -a- must be identical on both sides.
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3.2 Checking pistons and cylinder bores
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♦ Micrometre 75 - 100 mm - VAS 6071-
h re
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Measuring piston ring gap

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– Push piston ring at right angles to cylinder wall from above

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down into cylinder bore to approx. 15 mm from bottom end of

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Piston ring New Wear limit
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dimensions in mm (mm) (mm)
agen
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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 before check.
Piston ring New Wear limit
dimensions in mm (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

Caddy 2011 ➤
Checking piston
– Measure approx. 15 mm from lower edge, offset 90° from pis‐
ton pin axis with a 75 to 100 mm external micrometer.
• Maximum deviation from nominal dimension: 0.04 mm.
Nominal dimension ⇒ page 86 .
Note
Piston must be changed if piston shaft reveals cracking.
Measuring cylinder bore
Note
AG. Volkswagen AG d
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Cylinder bores must not be measured when yV
olksthe cylinder block is
w not
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secured to engine and gearbox support e - VAS 6095A- , as meas‐
d b ara
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urements may be incorrect. utho eo
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– Measure at three points -c-, in direction -a- and direction -b-.
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• Maximum deviation from nominal dimension: 0.10 mm.
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Nominal dimension ⇒ page 86 .
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3.3 Piston and cylinder dimensions

Piston ∅ Cylinder bore ∅
nform
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Basic di‐ mm 80.96 81.01

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3.4 Measuring piston projection at TDC

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♦ Measuring tool - VW382- t. Cop py
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Caddy 2011 ➤
♦ Measuring plate - VW 385/17-
♦ Dial gauge - VAS 6079- AG. Volkswagen AG d

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Test sequence
rrectne
♦ Piston projection at TDC must be measured on all pistons
when installing new pistons or a short engine.
ss o
♦ If you have measured the piston projection and it is not same
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for all pistons, use the highest value to determine the correct
form
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gasket size.
atio
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♦ Depending on piston projection, fit the appropriate cylinder

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head gasket according to following table. n thi

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♦ Turn the engine in an clockwise direction to carry out the

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Caddy 2011 ➤
– 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
in the longitudinal direction of the engine).
Piston projection at TDC must be measured when new pistons or
a short engine is installed. Install the appropriate cylinder head
gasket depending upon piston projection, according to following
table:
Piston projection over upper Identification
edge of cylinder block in mm Holes/notches
0.91 mm to 1.00 mm 1
1.01 mm to 1.10 mm 2
1.11 mm to 1.20 mm 3
3.5 Checking radial clearance of conrods

♦ Plastigage
Test sequence
– Remove conrod bearing cap. Clean bearing cap and bearing AG. Volkswagen AG d
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– Fit conrod bearing cap and tighten without turning further and
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without rotating crankshaft.

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– Remove conrod bearing cap again.

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– Compare width of Plastigage with the measurement scale.

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Radial clearance:
spec
• Wear limit: 0.08 mm.

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– Renew conrod bolts.

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Prote AG.

Caddy 2011 ➤
3.6 Separating new conrods

Procedure
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.
– Using a plastic hammer, carefully knock against conrod bear‐

ing cap -1- in direction of -arrow- until it is loose.
lkswage es n
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3.7 Removing and installing oil spray jets

es, in part or in w
t to the co

rrectness of i
l purpos
nform
mercia
a
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tion in
r
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t.
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Cop py
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♦ Torx bit T40 - T10545-
co Vo
by lksw
cted agen
Prote AG.

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
– Align guiding edge of oil spray jet with machined surface of
cylinder block.
Torque settings
Oil spray jet with 24 Nm
pressure relief
valve
AG. Volkswagen AG d
agen oes
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nl
pt
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
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sd
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ng
t.
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Cop py
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pyri by
Vo
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by c lksw
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Prote AG.

Caddy 2011 ➤
4 Crankshaft
⇒ “4.1 Assembly overview - crankshaft”, page 91
⇒ “4.2 Crankshaft dimensions”, page 92
⇒ “4.3 Measuring axial clearance of crankshaft”, page 92
⇒ “4.4 Measuring radial clearance of crankshaft”, page 93
⇒ “4.5 Renewing needle bearing in crankshaft”, page 93
⇒ “4.6 Renewing spur gear for crankshaft”, page 95
4.1 Assembly overview - crankshaft
1 - Bearing shells 1, 2, 4 and 5

❑ For bearing cap without
oil groove.
❑ For cylinder block with
oil groove
❑ Do not interchange
used bearing shells
(mark).
2 - Bolt
❑ Renew after removal AG. Volkswagen AG d
agen
❑ To measure radial clear‐ Volksw
oes
not
gu
ance, tighten to 65 Nm d by ara
se nte
but not further. thori
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❑ 65 Nm +90° ss a c
ce
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un
3 - Bearing cap
pt
an
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❑ Bearing cap 1: belt pul‐ y li

erm
ley end. ab
ility
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❑ Bearing cap 3 with re‐

wit
is n
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cesses for thrust wash‐
ole,
ers.
spec
❑ Bearing shell retaining

t to the co
lugs in cylinder block

and bearing caps must
align.
rrectne
4 - Thrust washer
s
❑ For bearing cap 3.

s o
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❑ Note fixing arrange‐

inform
ment.
mer
atio
m
5 - Bearing shell 3
o
n
c
i
or
❑ For bearing cap without

thi
e
oil groove.
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❑ For cylinder block with

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❑ Do not interchange used bearing shells (mark). C py
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6 - Needle bearing cop Vo
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❑ Only vehicles with dual clutch gearbox. Prote AG.

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…0.08 mm; wear limit: 0.17 mm
4. Crankshaft 91
Caddy 2011 ➤
❑ Do not rotate crankshaft when checking radial clearance
❑ Crankshaft dimensions ⇒ page 92 .
8 - Thrust washer
❑ For cylinder block, bearing 3
AG. Volkswagen AG d
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4.2 Crankshaft dimensions
ol not
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(Dimensions in mm)
aut
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Crankshaft Conrod
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pt
main journal ∅ journal ∅
an
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itte
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rm
Basic dimension 54.00 -0.022 50.90 -0.022
ab
pe
ility
-0.042 -0.042
ot
wit
, is n
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4.3 Measuring axial clearance of crankshaft
hole
spec
es, in part or in w
t to the co
♦ Universal dial gauge holder - VW 387-
rrectness of i
l purpos
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a
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tion in
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te o
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Cop py
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♦ Dial gauge - VAS 6079- opyri
gh by
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Prote AG.
Procedure
– Attach dial gauge - VAS 6079- with universal dial gauge holder
- VW 387- to cylinder block as shown in illustration and set
against crank web.
– Press crankshaft against dial gauge by hand.
– Set dial gauge to “0”.
– Push crankshaft away from dial gauge and read off measured
value.
Axial clearance:
• New: 0.07 to 0.17 mm.
• Wear limit: 0.37 mm

Caddy 2011 ➤
4.4 Measuring radial clearance of crank‐

shaft
♦ Plastigage
Procedure
– Remove bearing cap and clean crankshaft journal.
– Place a Plastigage corresponding to the width of the bearing
on the journal or into the bearing shells.
• The Plastigage must be in the middle of the bearing shell.
– Fit bearing cap and tighten. Do not rotate crankshaft.
– Remove bearing cap again.
Radial clearance:
• New: 0.03 ... 0.08 mm
4.5 Renewing needle bearing in crankshaft

Vehicles with dual clutch gearbox only.
wage
e ks s no
Vol t gu
♦ Adapter - Kukko 22/1- ed by ara
ris nte
tho eo
au ra
c
ss
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rm
ab
pe
ility
ot
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es, in part or in w
t to the co
rrectness of i
♦ Puller - Kukko 21/2-

l purpos
nform
mercia
a
com
tion in
r
te o
thi
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Cop py
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Prote AG.
4. Crankshaft 93
Caddy 2011 ➤
♦ Pin - VW 207 C-
AG. Volkswagen AG d
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es, in part or in w
t to the co
Note
rrectness of i
Vehicles with dual clutch gearbox, the needle bearing must be
l purpos
installed in rear end of crankshaft.
nf
ercia
Condition:
orm
m
• Always renew needle bearing -arrow- after separating engine
atio
m
and gearbox.
o
n in
or c
thi
e
• The front edges of the inner puller must not be chipped.

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rig ht
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Prote AG.
Pulling out needle roller bearing

– Using a commercially available internal puller, e. g. KUKKO -
21/2- , and counter support, e.g. KUKKO - 22/1- , pull needle
bearing -1- out of crankshaft -2-.
– The internal puller must be positioned behind the needle-and-
cage assembly -arrow-.

Caddy 2011 ➤
Installing
– Clean bearing seat in crankshaft and apply as thin coating of
grease. . Volkswage n AG n AG d
wage oe
– Drive needle bearing intoyV
olcrankshaft
ks to installation depth
s no
t gusing
ua
drift - VW 207 C- .ised b ran
r tee
ho
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nl
pt
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ab
ility
ot p
wit
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es, in part or in w
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rrectness of i
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Installation depth: dimension -a- = 1.5 mm … 1.8 mm
nform
ercia
Note
m
at
om
ion
c
in t
If the needle bearing is inadvertently driven in too far, it must be
or
his
e
renewed because it will be damaged when it is pulled out again.

at
do
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cum
for
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Cop py
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Prote AG.
4.6 Renewing spur gear for crankshaft

♦ Fitting tool - 10 - 203-
4. Crankshaft 95
Caddy 2011 ➤
♦ Puller - T10392-
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ab
♦ Thrust piece - T10392/1-
ility
ot p
wit
♦ Temperature gauge - VAS 6519- or hand-held multimeter -
, is n
h re
V.A.G 1526D- in combination with temperature sensor - V.A.G
hole
spec
1526D/1-
es, in part or in w
t to the co
♦ Commercially available hotplate
rrectness of i
l purpos
nform
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at
om
ion
c
in t
or
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ate
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Procedure t. Cop py
rig
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– Remove sealing flange (belt pulley end) ⇒ page 69 . pyri by
Vo
co lksw
by
cted agen
– Remove sump ⇒ page 166 . Prote AG.
– Remove balancer shaft module ⇒ page 190

Pulling off spur gear
– Insert thrust piece - T10392/1- in crankshaft stub.

Caddy 2011 ➤
– Insert puller - T10392- into holes of spur gear and turn clock‐
wise -arrow-, screw in locating pins -A-.
– Counterhold crankshaft with ring spanner -A-, pull spur gear

off crankshaft journal by screwing spindle in using ring span‐
ner -B- or ratchet.
Shrink-fitting spur gear
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
Note orise nte
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♦ Check temperature when heating the new drive pulley using s
ce
e
temperature gauge - VAS 6519- or hand-held multimeter -

nl
pt
du
an
V.A.G 1526D- in combination with temperature sensor - V.A.G
itte
y li
1526D/1- . To do this, push measuring tip of temperature sen‐
erm
ab
sor onto drive pulley.
ility
ot p
wit
, is n
♦ At a temperature of 200 °C, the drive pulley must be driven
h re
onto crankshaft within approx. 4 seconds.
hole
spec
es, in part or in w
♦ A higher temperature increases the available time (220 °C =

approx. 6 seconds). t to the co
♦ Ensure that crankshaft stub is clean.
rrectness of i
l purpos
Caution
nf
ercia
The maximum temperature of 240 °C must not be exceeded

orm
because this will lead to discolouring and possibly distortion of

m
atio
m
the drive pulley.

o
n in
or c
thi
te
sd
iva
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– Place new spur gear onto a commercially available hot plate

o
m
f
en
ng
and heat to at least 200 °C, maximum 240 °C. The lettering
t.
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op
faces upwards. C py
t. rig
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by c lksw
WARNING Prote
cted AG.
agen
There is a risk of burning. Wear suitable protective gloves for

further work.
4. Crankshaft 97
Caddy 2011 ➤
– When the temperature is reached, take spur gear up using

pliers, as shown in illustration.
Note
swage es n
Take care not to damage the teeth of the spur gear. byV
olk ot g
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d ran
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ab
pe
ility
ot
– Slide spur gear quickly by hand without canting onto crank‐
wit
, is n
h re
shaft end until stop using fitting tool - 10 - 203- .
hole
spec
– Allow the spur gear to cool down a few minutes and then install
es, in part or in w
t to the co
balancer shaft module ⇒ page 192 .
Torque settings
rrectness of i
♦ ⇒ “1.3 Assembly overview - sealing flange, belt pulley end”,
page 50
l purpos
♦ ⇒ “1.1 Assembly overview - sump/oil pump”, page 164
nform
ercia
♦ ⇒ “4.1 Assembly overview - balancer shaft module”,

page 187
m
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
rise
d b ara
nte Caddy 2011 ➤
autho
4-cylinder diesel engine (2.0
eo l
ra engine, common rail) - Edition 09.2016
ss c
ce
e
nl
pt
15 – Cylinder head, valve gear
du
an
itte
y li
erm
ab
ility
ot p
1 Cylinder head
wit
, is n
h re
hole
spec
⇒ “1.1 Assembly overview - cylinder head”, page 99
es, in part or in w
t to the co
⇒ “1.2 Assembly overview - cylinder head cover”, page 102
⇒ “1.3 Removing and installing cylinder head”, page 104
rrectness of i
⇒ “1.4 Removing and installing cylinder head cover”, page 117
l purpos
⇒ “1.5 Removing and installing vacuum pump”, page 120

⇒ “1.6 Checking compression”, page 121
nform
ercia
1.1 Assembly overview - cylinder head

m
at
om
ion
c
in t
or
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e
Note
at
do
priv
cum
for
♦ The plastic protectors fitted to protect the open valves must only be removed immediately before fitting the
en
ng
t.
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cylinder head.
Co
Cop py
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gh
♦ When cylinder head is renewed, the coolant must be completely renewed as well.
ht
pyri by
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cted agen
Prote AG.
1 - Cylinder head gasket

❑ Renew coolant and en‐
gine oil after replacing.
❑ Observe identification
⇒ page 101 .
2 - Bolt
❑ Insert with locking fluid
⇒ Electronic Parts
Catalogue .
❑ 10 Nm
3 - Hall sender - G40-
❑ For camshaft position.
⇒ page 378
4 - Cylinder head
❑ Must not be reworked.
❑ Before installing, check
that the two dowel
sleeves for centring cyl‐
inder head on cylinder
block are fitted.
❑ Renew coolant and en‐
gine oil after replacing.
❑ To prevent damage to
glow plugs, always
place cylinder head on a
soft foam surface after
removal ⇒ page 100 .
❑ Check for distortion
⇒ page 101
⇒ page 104
1. Cylinder head 99
Caddy 2011 ➤
5 - Washer
6 - Cylinder head bolt
❑ Sequence when loosening ⇒ page 101
7 - Oil pressure switch - F1- lkswage es n
o ot g
byV ua
❑ Switch pressure 0.3 to 0.6 bar ir se
d ran
tee
ho
❑ Removing and installing ⇒ page 179 aut or
ac
ss
❑ Checking ⇒ page 180
ce
le
un
pt
❑ 20 Nm
an
d
itte
y li
rm
ab
8 - Sealing ring
pe
ility
ot
wit
, is n
h re
9 - Bolt
hole
spec
❑ 20 Nm
es, in part or in w
t to the co
10 - Engine lifting eye
11 - Sealing ring
rrectness of i
l purpos
12 - Bolt
❑ 20 Nm
nform
ercia
13 - Seal
m
a
com
ti
on in
r
te o
thi
14 - Vacuum pump
s
iva
do
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rp
cum
fo
en
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15 - Bolt
n
t.
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❑ 10 Nm t. C rig
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16 - Union
co Vo
by lksw
cted agen
Prote
❑ With coolant temperature sender - G62-
AG.
17 - Bolt
❑ 9 Nm
18 - Seal
19 - Bolt
❑ 20 Nm
20 - Engine lifting eye
Glow plugs -arrows- project out of cylinder head.

Glow plugs -arrow- project out of cylinder head. After removal, the
cylinder head must not be placed on the glow plugs. If necessary,
remove glow plugs ⇒ page 374 .
100 Rep. gr.15 - Cylinder head, valve gear

Caddy 2011 ➤
Checking cylinder head for distortion

♦ Straightedge 500 mm - VAS 6075-
♦ Feeler gauge -1-
Max. permissible distortion: 0.1 mm
Note
Cylinder heads for TDI engines

agen
AG. Volksmust
wagennot
AG dbe reworked. oes
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by
Cylinder headris
e gasket
d identification ara
nte
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1 - Partau number ra
c
ss
ce
le
2- Holes
un
pt
an
d
itte
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3- Ignore
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
Different thicknesses of cylinder head gasket are fitted depending

t to the co
on the piston projection. If only cylinder head gasket is removed,

install a new cylinder head gasket with same identification.
rrectne
Observe sequence when loosening cylinder head bolts

ss o
cial p
– Slacken cylinder head bolts in the sequence -1 … 10-.

inform
mer
atio
om
n
c
i
or
n thi
te
sd
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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.
1. Cylinder head 101

Caddy 2011 ➤
Cylinder head - specified torque and sequence
Note
Renew bolts for cylinder head.

1 -1 to 10- 30 Nm
2 -1 to 10- 50 Nm
3 -1 to 10- Turn 90° further
1.2 Assembly overview - cylinder head cover
1 - Seal
❑ Renew if damaged or
leaking
swage es n
2 - Cylinder head cover byV
olk ot g
ua
d ran
❑ Removing and installing o
ir se tee
⇒ page 117 auth or
ac
ss
3 - O-ring
ce
e
nl
pt
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itte
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erm
ab
4 - Hose
ility
ot p
❑ For crankcase breather
wit
, is n
h re
system
hole
spec
❑ Press release buttons to
es, in part or in w
detach
5 - Sealing bushing t to the co
❑ For fuel rail
rrectness of i
❑ Renew if damaged or
l purpos
leaking
6 - Retainer
nf
ercia
❑ For electrical cables

rm
m
atio
m
7 - Grommet
o
n in
or c
8 - Clamping piece
thi
te
sd
iva
o
r
9 - Bolt
rp
cu
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m
f
en
ng
❑ 8 Nm
t.
yi Co
op py
10 - High-pressure accumula‐
t. C rig
gh ht
yri
tor p by
co Vo
by lksw
❑ Do not attempt to re‐
cted agen
Prote AG.
shape high-pressure
lines.
❑ Comply with rules for
cleanliness ⇒ page 7
❑ Installing high-pressure lines ⇒ page 304 .
11 - Bolt
❑ 22 Nm

Caddy 2011 ➤
12 - Bolt
❑ 8 Nm +180°
13 - Fuel return pipe
14 - O-ring
15 - Injector
❑ Comply with rules for cleanliness ⇒ page 7
16 - O-ring
17 - Heat shield seal
18 - Sealing ring
❑ For injector n AG. Volkswagen AG do
swage es n
❑ Renewing ⇒ page 313 byV
olk ot g
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d ran
ir se
19 - Cap tho tee
or
au ac
20 - Seal ss
ce
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un
❑ For sealing cover
pt
an
d
itte
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21 - Grommet
rm
ab
pe
ility
22 - Retainer
ot
wit
, is n
h re
hole
spec
23 - Bolt
es, in part or in w
t to the co
❑ Renew gasket if damaged
rrectness of i
❑ 9 Nm
l purpos
Tightening sequence for cylinder head cover

nform
ercia
– Tighten cylinder head cover bolts in the sequence -1 … 6-.

m
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
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
G. Volkswagen AG d
1.3 Removing and installing cylinder head
olks
wage
nA oes
not
yV gu
db ara
rise nte
Special tools and workshop tho eo
au ra
equipment required ss c
ce
e
nl
pt
♦ Guide pin - 3070-
du
an
itte
y li
erm
♦ 2x diesel injection pump
ab
ility
locking pin - 3359-
ot p
wit
, is n
♦ Crankshaft stop - T10050-
h re
hole
spec
♦ Counterhold tool - T10051-
es, in part or in w
t to the co
♦ Puller - T10052-
♦ Bit XZN 10 - T10385-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
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f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Torque wrench
(5 … 50 Nm) - V.A.G 1331-
♦ Hose clip pliers - VAS
6362-
♦ Socket set 1/4", 22-piece -
VAS 5528-
♦ Engine bung set - VAS
6122-
♦ Drip tray for workshop hoist
- VAS 6208-
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
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itte
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erm
ab
♦ Removal lever - 80 - 200-
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Ratchet ring spanner - T10384- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
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Note
♦ All cable ties that are opened or cut through when the engine
is removed must be renewed/replaced in the same position
when the engine is installed.
♦ Seal open lines and unions with clean plugs from engine bung
set - VAS 6122- .
♦ Collect drained coolant in a clean container for re-use or dis‐
posal.
♦ Route lines of any kind so that the original routing can be re‐
stored.
♦ Ensure sufficient clearance to all moving or hot components.
Removing
Rep. gr. 50 ; Plenum chamber bulkhead; Removing and in‐
stalling plenum chamber bulkhead .
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.
27 ; Battery; Removing and installing battery tray
– Remove radiator cowl with radiator fan ⇒ page 226 .

Caddy 2011 ➤
– Detach vacuum line -2- from vacuum pump -1-. agen

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– Unclip vacuum lines -1 and 2-.
rrectne
– 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.
ss o
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– Remove air hose. To do this, loosen hose clips -1- and -2-. t. C rig
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– Remove cylinder head cover ⇒ page 117 .
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– Undo connection -arrow- of vacuum line.

Caddy 2011 ➤
– Unclip engine pre-wiring harness from bracket -arrow-.
– Pull off connector -2- from throttle valve module - J338- with
throttle valve potentiometer - G69- .
– Remove bolt -4- from dipstick connection.
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– Remove bolts -2-, -5- and -arrows-.
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– Free electrical wiring and hoses on left air pipe using removal
lever - 80 - 200- .
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– Loosen hose clip -3- and remove left air pipe.
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– Unscrew bolts -arrows- and remove pulsation damper -2-.
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Note
Disregard -item 1-.

– Disconnect connector -4- at coolant temperature sender -
G62- .

Caddy 2011 ➤
– Pull coolant hoses off connection. To do this, loosen hose clips

-1- and -2-.
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– Detach connector -1- from oil pressure switch - F1- .
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– Unscrew bolt -arrow-.
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– Pull off vacuum line -2- and place to one side.
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– Detach these connectors:
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♦ -3- Lambda probe - G39-
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separate.
on turbocharger.

Caddy 2011 ➤
– Undo and remove bolts -arrows- from charge air pipe and de‐
tach connector from charge pressure sender - G31- -1-.
– Open clamp -2-.
– Detach coolant hose -3- from retainers and remove charge air
pipe.
Caution
Ensure that flexible joint of connecting pipe is not bent and thus
stretched. There is a danger of cracking.
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– Undo nuts -arrows- of particulate filter bracket -A- at crank‐
oris tee
case. auth or
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– Remove oil line for turbocharger and turbocharger support
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⇒ page 198 .
– Unscrew union nuts -2-, and unscrew bolt -3-.
nf
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Note
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Disregard -item 1-.

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– To create space for removing and installing the oil supply line Prote AG.
with turbocharger support, remove fastening clip -1- between
particulate filter and turbocharger.

Caddy 2011 ➤
– Unscrew bolt of bracket on cylinder head -arrow- and push

particulate filter to one side.
– Loosen securing nuts above particulate filter bracket -1- using

ratchet wrench, 13 mm - T10384- .
– Unscrew securing nuts -2- for particulate filter bracket on
crankcase.
AG. Volkswagen AG d
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– Now you can access the bolt of the retaining clamp -arrow- for
rrectness of i
the oil return line on the turbocharger support. Unscrew bolt
-arrow-.
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– Remove connecting pipes -A- leading to cooler for exhaust
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Caddy 2011 ➤
– Remove coolant hoses from connections, loosen hose clips

-1- and -2- for this.
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– Detach connector for Hall sender - G40- -arrow-.
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Fit support bracket - 10 - 222 A- with the necessary adapters as
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shown and take up weight of engine in installation position
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– Removing engine mounting completely ⇒ page 11 .
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– Remove engine bracket ⇒ page 61 .

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– Unscrew and remove bolt -arrow- of rear toothed belt guard.

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– Remove toothed belt from camshaft and high-pressure pump
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⇒ page 125 .
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– Install engine bracket again, tightening old bolts by hand Prote
cted AG.
agen
⇒ page 61 .
– Install assembly mountings again, tightening old bolts by hand
⇒ page 32 .
– Remove support bracket - 10 - 222 A- .
– Remove camshaft sprocket from hub.
– Remove camshaft hub. To do this, pull camshaft hub off using
puller - T10052- .
– Counterhold hub with counterhold - T10051- and release hub

bolt -1-.
– Unscrew hub bolt approx. 2 turns.

Caddy 2011 ➤
– 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.
– Observe correct sequence when loosening cylinder head

bolts.
Note
♦ A second mechanic is required for the removal of the cylinder

head.
♦ The toothed belt tensioning roller is pulled off the stud when
the cylinder head is lifted out.
♦ The oil return line of the turbocharger is pulled out of the sup‐
port when the cylinder head is lifted out.
– First raise cylinder head on gearbox side and pull slightly to

left. Whilst doing this, remove toothed belt tensioner from stud.
Caution
Risk of damage to glow plug pins -arrow- when cylinder head

is being lowered.
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113
Prote AG.
1. Cylinder head
Caddy 2011 ➤
– Place the cylinder head of a surface in such a way that the oil
return line is not bent. To do this, place a piece of wood under
the exhaust manifold if necessary.
Caution
Avoid damage to sealing surfaces:

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♦ When using abrasive paper do not use a grade
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head and cylinder block. Ensures that no long scores or
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Avoid damage to cylinder block.
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♦ No oil or coolant may be contained in hole pockets for cyl‐

inder head bolts in cylinder block.
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Danger of cylinder head gasket leaks.

m
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♦ Do not remove new cylinder head gasket from packaging
om
ion
until it is ready to be fitted.
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♦ Handle the cylinder head gasket very carefully to prevent

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damage to the silicone coating or the indented area of the

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removed until the cylinder head is ready to be fitted.
Avoid damage to valves and piston crowns after working on
valve gear.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.

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 headwagasket.
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♦ If parts of the crankshaft
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♦ When renewing cylinder head or cylinder head gasket, entire
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coolant ⇒ page 207 and engine oil ⇒ Maintenance ; Booklet

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39 must be replaced. h re
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– Note cylinder head gasket identification:

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

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wards.
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– Before fitting cylinder head, remove crankshaft stop and turn

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crankshaft opposite direction of rotation until all pistons are

o
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nearly uniformly below TDC.

thi
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– Cylinder head gasket must lie with identification facing up‐

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Prote AG.

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

on intake side.
Note
Tensioning roller must be pushed onto studs when fitting cylinder

head.
– 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. . Volkswage n AG n AG d
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– Unscrew guide pins -3070/9- through bolt holes in Vcylinder
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head and screw remaining cylinder head bolts d by hand until
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– Tighten cylinder head in 4 stages in sequence shown as fol‐
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1- Tighten initially with torque wrench:
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Stage I = 30 Nm
t to the co
Step II = 50 Nm
2- Turn further with rigid spanner:
rrectne
Stage III = 90°
s
Stage IV = 90°
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– Install hub and camshaft sprocket.
nform
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– Lock camshaft and high-pressure pump with diesel injection

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pump locking pin - 3359- .

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– Turn crankshaft to TDC in direction of engine rotation, and lock

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crankshaft using crankshaft stop - T10050- or crankshaft stop

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- T10490- .
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– Fit toothed belt in position and adjust valve timing
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Caddy 2011 ➤

– Install cylinder head cover ⇒ page 117 .
– Install poly V-belt ⇒ page 53 .
– Reconnect battery earth strap with ignition switched off ⇒
Electrical system; Rep. gr. 27 ; Disconnecting and reconnect‐
ing battery .
– Perform road test,wageand read event memory
es n ⇒ Vehicle diag‐
s
nostic tester.
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♦ ⇒ss “1.2 Assembly overview - cylinder head cover”, page 102
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♦ ⇒ “1.1 Assembly overview - cylinder head”, page 99
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♦ ⇒ “4.1 Assembly overview - exhaust gas recirculation”, t to the co
page 369
rrectness of i

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1.4 Removing and installing cylinder head

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Caddy 2011 ➤
♦ Socket - T40055-
Observe safety precautions ⇒ page 4 .

Comply with rules for cleanliness ⇒ page 7
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Removing Volksw
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– Disconnect electrical connector -2- on exhaust gas pressureorise nte
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sensor 1 - G450- . auth
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– Unscrew bolt -3-, pull exhaust gas pressure sensor 1 - G450-
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from bracket -arrow- and lay aside.
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Disregard -item 1-.
spec
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– Release clips -arrows- and press upper toothed belt guard
aside to the right.
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– Remove injectors ⇒ page 298 .
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mer
– Remove fuel rail ⇒ page 309 .
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– Remove crankcase breather hose -1- from cylinder head cov‐ Prote AG.
er; press release buttons for this.
Note
Disregard -item 2- and -arrows-.

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 vacuum lines from bracket on cylinder head cover.
– Release and unscrew bolts for cylinder head cover in the se‐
quence -6…1-.
– Remove cylinder head cover. AG. Volkswagen AG d
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♦ Renew gasket for cylinder head cover and bolts for cylinder
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head cover if damaged or leaking.
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♦ Renew grommets and seals for injectors if damaged or leak‐
erm
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– Hand-tighten cylinder head cover in the sequence -1 … 6-.
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– Tighten bolts in the sequence -1 … 6-.
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Caddy 2011 ➤
– Ensure that cylinder head cover is correctly clipped to toothed

belt guard -arrows-.
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For reasons of clarity,
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camshaft sprocket removed.
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– Check clearance between hub and toothed belt guard.
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– Install coolant return line.
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– Install intake pipe ⇒ page 249 .
ole,
spec
– Install injectors ⇒ page 298 .
t to the co
– Install fuel rail ⇒ page 309 .
– Install exhaust gas pressure sensor 1 - G450-
rrectne
Torque settings
ss
♦ ⇒ “1.2 Assembly overview - cylinder head cover”, page 102
o
cial p
f inform
1.5 Removing and installing vacuum pump
mer
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DANGER!
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The vacuum pump may, under no circumstances, be disman‐

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tled as the vacuum part could otherwise malfunction. This

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would result in failure of the brake servo. Cop py
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Removing
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pipe ⇒ page 341 .
– Detach vacuum line -2- from vacuum pump -1-.
– Undo and remove bolts of charge air pipe
⇒ Item 19 (page 240) .
– Then push charge air pipe down slightly to gain access to rear
threaded connection of vacuum pump.
– Place cloths under vacuum pump -1-.

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or ➤
u
4-cylinder dieselss engine (2.0 l engine, common rail) - Edition 09.2016
a ac
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– Unscrew bolts -arrows- from vacuum pump.
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– Remove vacuum pump from cylinder head.
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Note
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♦ Ensure that vacuum pump coupling seats properly in cam‐
shaft.
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♦ Vacuum pump has been correctly seated in camshaft if it is
lying completely against cylinder head.
nform
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♦ The seal must be renewed.
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Torque settings
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ate
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1.6 Checking compression
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Special tools and workshop equipment required Prote AG.
♦ Compression tester - V.A.G 1763-
Procedure
• Engine oil temperature min. 80°C
• Battery voltage at least 12.5 V.
– Disconnect electrical connector from fuel pressure regulating
valve - N 276- -arrow- on fuel rail.
– Start engine briefly to reduce fuel pressure in fuel rail.
– Remove glow plugs ⇒ page 374 .

Caddy 2011 ➤
– Screw in adapter - V.A.G 1763/8- in each place where glow

plugs were and connect compression tester - V.A.G 1763- .
– Check compression using compression tester - V.A.G 1763- .
Using compression tester ⇒ operating instructions .
– Have a 2nd mechanic operate starter until tester shows no
further pressure increase.
Compression pressures bar
New 25.0 to 31.0
Wear limit 19.0
Maximum difference between cylinders 5.0
– Read engine control unit event memory and clear entries
⇒ Vehicle diagnostic tester.
AG. Volkswagen AG d
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Prote AG.

Caddy 2011 ➤
2 Toothed belt drive

⇒ “2.1 Assembly overview - toothed belt drive”, page 123
⇒ “2.2 Removing and installing toothed belt”, page 125
2.1 Assembly overview - toothed belt drive
1 - Toothed belt
❑ Mark direction of rota‐
tion before removing
❑ Check for wear
❑ Do not kink
⇒ page 125 .
2 - Bolt
❑ 20 Nm +45°
3 - Camshaft sprocket
4 - Tensioning pulley
❑ To remove, remove en‐
gine bracket
⇒ page 61 .
5 - Bolt lkswage es n
o ot g
❑ 100 Nm byV ua
d ran
ir se tee
o
6 - Hub auth or
ac
ss
ce
e
nl
⇒ page 143 .
pt
du
an
itte
y li
7 - Stud
erm
ab
ility
ot p
❑ 15 Nm
wit
, is n
h re
8 - Idler roller
hole
spec
9 - Bolt
es, in part or in w
t to the co
❑ Specified torque
⇒ page 316
10 - Toothed belt pulley on
rrectness of i
high-pressure pump
l purpos
11 - Bolt
❑ 15 Nm
nf
ercia
orm
12 - Idler roller
m
atio
om
13 - Toothed belt guard

n in
or c
thi
e
❑ Rear
t
sd
iva
o
r
rp
cu
14 - Bolt
o
m
f
en
ng
❑ 20 Nm
t.
yi Co
Cop py
.
15 - Bolt
t rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
❑ 10 Nm
AG.
16 - Nut
❑ 20 Nm +45°
2. Toothed belt drive 123

Caddy 2011 ➤
17 - Bolt
❑ 50 Nm +90°
18 - Hub
❑ Removing and installing ⇒ page 317 .
19 - Nut
❑ Specified torque ⇒ page 316
20 - Coolant pump
21 - Bolt
❑ 15 Nm
22 - Stud
❑ 15 Nm
23 - Idler roller
24 - Nut
❑ 20 Nm
25 - Crankshaft pulley
26 - Bolt
❑ Do not additionally oil or grease the threads and shoulder
❑ Turning further can be done in several stages.
❑ 180 Nm +135° en AG. V
olkswagen AG
ag does
ol ksw not
27 - Toothed belt guard
yV gu
edb ara
❑ Upper part
ho
ris nte
eo
t
au ra
28 - Toothed
ss belt guard c
ce
le
❑ Lower part
un
pt
an
d
itte
y li
29 - Bolt
rm
ab
pe
ility
❑ 9 Nm
ot
wit
, is n
30 - Belt pulley and vibration damper

h re
hole
spec
❑ Can only be installed in one position, holes are offset.

es, in part or in w

t to the co
31 - Bolt
rrectness of i
❑ 10 Nm +90°
l purpos
32 - Bolt
nform
ercia

m
a
com
tio
❑ 40 Nm +180°
n in
r
te o
thi
33 - Engine support
s
iva
do
r

rp
cum
fo
en
ng
34 - Bolt
t.
yi Co
Cop py
❑ 9 Nm ht. rig
rig ht
py by
o Vo
35 - Protective plate by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Lower toothed belt guard
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
2.2 Removing and installing toothed belt
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
equipment required
♦ 2x diesel injection pump
rrectness of i
locking pin - 3359-
l purpos

nf
ercia
o
♦ Angled screwdriver -
rm
m
T10264-
atio
om
n in
c
♦ Locking tool - T10265-

or
thi
te
sd
a
♦ Bit XZN 10 - T10385-

iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Angled screwdriver - T10409-
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
Note
thi
te
sd
iva
o
r
2 versions of tensioning roller are fitted. They are not interchange‐

p
cum
r
fo
able. When performing adjusting measures, check first to see

en
ng
t.
yi
which tensioning roller is installed.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
126
Prote AG.
Rep. gr.15 - Cylinder head, valve gear
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
orise nte Caddy 2011 ➤
h eo
aut 4-cylinder diesel engine (2.0 ra l
c
engine, common rail) - Edition 09.2016
ss
ce
e
nl
Observe different directions of rotation during tensioning
pt
du
an
itte
y li
Features of tensioning roller A:
erm
ab
ility
ot p
♦ Locking tool - T10265- required for installation.
wit
, is n
h re
♦ Check tensioning roller is seated correctly in timing belt guard.
hole
spec
♦ Tension toothed belt by turning tensioning roller eccentric
es, in part or in w
t to the co
»clockwise«
Features of tensioning roller B:
rrectness of i
♦ Locking tool not required.
l purpos
♦ Tensioning roller is not seated in toothed belt guard.

♦ Tension toothed belt by rotating tensioning roller eccentric
nf
ercia
»anticlockwise«
orm
m
atio
Removing
om
n in
or c
thi
te
sd
a
Note
iv
o
r
rp
cu
o
m
f
en
ng
The toothed belt may only be adjusted on cold engines, as the

t.
yi Co
op
indicator position on the tensioning element varies depending on C py
t. rig
the engine temperature.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote
– Remove fuel filter ⇒ Rep. gr. 20 ; Fuel filter; Removing and
AG.
installing fuel filter .

– Remove supplementary fuel pump - V393- ⇒ Rep. gr. 20 ;
Supplementary fuel pump - V393- ; Removing and installing
supplementary fuel pump - V393- .
– Pull connector from radiator outlet coolant temperature sender

- G83- . Open clips -arrows- and remove toothed belt guard.

– Push washer fluid reservoir filler pipe with filler neck -2- to side.
Note
♦ Disregard -item 3-.

♦ For reasons of clarity, diagram shows installation position with
fuel filter removed.

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
nf
ercia
orm
m
– Disconnect electrical connector -3- on radiator outlet coolant

atio
m

o
n in
or c
thi
– Unscrew nut -1- and bolt -2-.

te
sd
iva
o
r
rp
cu
– Move right coolant pipe along with connected hoses -arrows-

o
m
f
to side.
en
ng
t.
yi Co
op
– Remove front right lower wheel housing liner ⇒ General body
C py
ht. rig
repairs, exterior; Rep. gr. 66 ; Wheel housing liner .
rig ht
py by
co Vo
by lksw
cted
– Remove vibration damper ⇒ page 60 .
agen
Prote AG.

Caddy 2011 ➤
4-cylinder
. Volkswage
diesel engine (2.0 l engine, common rail) - Edition 09.2016
AG n AG d
agen oes
olksw not
– Unscrewdbolts by
V -arrows-. gu
ara
rise nte
– Removetho lower toothed belt guard. eo
s au ra
c
s
– Turn crankshaft by bolt for toothed belt sprocket until toothed
ce
e
nl
belt for camshaft is at “TDC”.
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
– Fix the hub in place with locking pin for diesel injection pump
or c
thi
- 3359- .
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
Note
t.
yi Co
Cop py
t. rig
gh
-Arrows- can be disregarded.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Version A: lock crankshaft pulley with mark in position

– Lock crankshaft pulley in position with crankshaft stop -
T10050- .
• Marks on toothed belt pulley -2- and crankshaft stop - T10050-
-1- must align.
• Pin of crankshaft stop - T10050- must engage in drilling in
sealing flange.
• The crankshaft stop - T10050- can be pushed onto the toothed
belt pulley only from the face side.
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.

Caddy 2011 ➤
Version B: lock crankshaft pulley without mark in position
Note
olkswagen AG
en AG. V
Use only the crankshaft stop - T10490- to lock crankshaft
olks pulleys
wag does
not
without a mark in position. ed
byV gu
ara
ris nte
utho eo
– Lock crankshaft pulley in position withss crankshaft
a stop - ra
c
T10490- .
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
in sealing flange.
h re
hole
spec
es, in part or in w
Continued for all
t to the co
– Loosen bolts -arrows- approx. 90°.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
or
– Loosen bolts -arrows- by approx. 90° using bit XZN 10 -

f
en
ng
t.
yi
T10385- .
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Tensioning roller A:
– Loosen securing nut of tensioning roller -1- and turn tensioning
roller eccentric using socket - T10264- counter-clockwise
-arrow- until tensioning roller can be locked with locking pin -
T10265- .

Caddy 2011 ➤
– Turn tensioning roller eccentric clockwise -arrow- as far as

stop. Tighten nut -1- hand-tight.
Tensioning roller B:
– Loosen tensioning roller securing nut. Use socket - T10409-
to rotate eccentric of tensioning roller clockwise until tension‐
ing roller is relieved of tension. The tensioner of the tensioning
roller should now be in the 9 o'clock position approximately.
– Retighten securing nut by hand.
Continuation for both tensioning rollers
Caution
Risk of irreparable damage if direction of rotation is reversed

on previously used toothed belt. olkswage es n
ot V gu
by ara
♦ Before removing toothed belt, mark direction
or
ise
d
of rotation nte
with chalk or felt tipped pen for installation
auth purposes. eo
ra
ss c
ce
le
un
pt
– Mark direction of rotation of toothed belt.
an
d
itte
y li
rm
ab
– Remove toothed belt first from idler pulley and then from re‐
pe
ility
maining toothed belt pulleys.
ot
wit
, is n
h re
Installing
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ The toothed belt may only be adjusted on cold engines, as the

l purpos
indicator position on the tensioning element varies depending

on the engine temperature.
nform
ercia
♦ If the tensioning roller is to be renewed, the engine bracket

m
must be removed ⇒ page 61 .

a
com
tion in
♦ Renew securing bolts for camshaft pulley and high-pressure

r
te o
thi
pump pulley.
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 ➤
• The tensioning roller must be locked using locking tool -
T10265- and secured to right stop.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
– Set tensioner of tensioning roller to 9 o'clock position.
t to the co
– Attach tensioning roller provisionally.
• Crankshaft locked in position using crankshaft stop - T10050-
rrectness of i
or crankshaft stop - T10490- .
l purpos
nform
ercia
Note
m
at
om
ion
c
If necessary, turn camshaft hub with counterhold - T10172- and
in t
or
his
e
adapters - T10172/4- until camshaft can be secured in position.

at
do
riv
To do this, hand-tighten at least one securing bolt -1-.

p
cum
for
en
ng
t.
yi Co
op
– Fix the hub in place with locking pin for diesel injection pump
C py
t. rig
gh
- 3359- . To do this, insert locking pin through outer free elon‐
ht
pyri by
Vo
gated hole into hole in cylinder head.
co lksw
by
cted agen
Prote AG.
– Loosen hand-tightened bolts again.

It should just be possible to turn camshaft toothed belt pulley
without axial movement.
Note
If necessary, turn hub of high-pressure pump at bolt heads with

screwdriver until it can be secured in position.

Caddy 2011 ➤
Positioning hub of high-pressure pump AG. Volkswagen AG d

agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Turn the high-pressure pump with locking pin for diesel injec‐
m
at
om
tion pump - 3359- . To do this, push locking pin into adjustment
ion
c
hole outside toothed belt pulley.
in t
or
his
ate
Loosely tightened bolts -1-.
do
priv
cum
or
It should just be possible to turn high-pressure pump toothed belt

f
en
ng
t.
pulley without axial movement.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– 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
– Undo the nuts of the tensioning roller and pull out locking tool
- T10265- .

Caddy 2011 ➤
Note
Ensure that tensioning roller is seated correctly in rear toothed

belt guard -arrow-.
– Carefully turn eccentric of tensioning roller clockwise using

angle driver - T10264- . Indicator -2- must be roughly past the
centre of the gap in the base plate (corrects itself during pre‐
tensioning).
Ensure that securing nut -1- does not turn as well.
– Hold tensioning roller in this position and tighten securing nut
of tensioning roller.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
is nte
– Fit counterhold - T10172- as shown. Press counterhold
thor - eo
T10172- in -direction of arrow- and keep camshaft
s au pulley in ra
c
pretensioning position. s
ce
le
un
pt
– In this position, first hand-tighten bolts -1- of camshaft pulley
an
d
itte
y li
and of toothed belt pulley for high pressure pump and then
erm
ab
tighten to correct torque.
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Carefully turn eccentric of tensioning roller anticlockwise using
angle driver - T10409- . Indicator -2- must be roughly past the
ss
centre of the gap in the base plate (corrects itself during pre‐
o
cial p
f i
tensioning).
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
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.
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
– First hand-tighten securing bolts -arrows- for camshaft pulley
erm
ab
and then tighten to correct torque.
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
– First hand-tighten securing bolts of high-pressure pump tooth‐ orm

m
atio
m
ed belt pulley and then tighten to specified torque.

o
n in
or c

thi
te
sd
iva
o
r
– Remove locking pin for diesel injection pump - 3359- and

rp
cu
o
crankshaft stop - T10050- or crankshaft stop - T10490- .

f
en
ng
t.
yi Co
op
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐ C py
t. rig
gine's direction of rotation until crankshaft is at a position
gh ht
pyri by
shortly before “TDC”.
o Vo
by c lksw
cted agen
Prote AG.
– Fit crankshaft stop - T10050- or crankshaft stop - T10490- on
crankshaft pulley again.
– Turn crankshaft in direction of engine rotation until pin of
crankshaft stop engages in sealing flange whilst turning.

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 whether:
♦ The hub can be fixed in place with the locking pin for diesel
injection pump - 3359- .
♦ Tensioning roller indicator is centred or maximum 5 mm to
right of base plate notch.
Correcting the valve timing:
– 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 engine rotation until
camshaft hub can be locked in position.
– After locking, loosen bolts for toothed belt sprocket of cam‐
shaft.
A - pin of crankshaft stop - T10050- or crankshaft stop - T10490-
is to the left of hole:
– Turn crankshaft in direction of engine rotation until pin of
crankshaft stop engages in sealing flange whilst turning.
– Tighten bolts for camshaft toothed belt pulley.
B - pin of crankshaft stop - T10050- or crankshaft stop
agen
-AT10490-
G. Volkswagen AG d
is to the right of hole: Volksw
oes
not
g y ua
db ran
– First, turn crankshaft a little in directionris opposite to engine's
e
tee
ho
direction of rotation. au
t or
ac
ss
– Turn crankshaft in engine's direction of rotation again until
ce
le
un
pt
crankshaft stop pin engages in sealing flange whilst turning.

an
d
itte
y li
erm
– Tighten bolts for camshaft toothed belt pulley.

ab
ility
ot p
Continuation
wit
is n
h re
ole,
– Remove locking pin for diesel injection pump - 3359- and

spec
crankshaft stop .
t to the co
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐

rrectne
– Check valve timing again.

ss
– If camshaft hub can be secured in position, tighten securing

o
cial p
bolts as follows:
inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
♦ Camshaft pulley: tighten bolts. Counterhold with counterhold

- T10172- and adapters - T10172/4- .
♦ High-pressure pump pulley: tighten bolts. Counterhold with
counterhold - T10172- and adapters - T10172/8- .
– Install middle and lower toothed belt guards.
– Install vibration damper/belt pulley.
– Install upper toothed belt guard.
– Install wheel housing liner ⇒ General body repairs, exterior;
Rep. gr. 66 ; Wheel housing liner .
– Install noise insulation (if applicable) ⇒ General body repairs,
exterior; Rep. gr. 66 ; Noise insulation .
Torque settings agen
AG. Volkswagen AG d
oes
olksw not
V gu
♦ ⇒ “2.1 Assembly overview - assembly mountings”,
ed by page 32 ara
nte
ris
o eo
♦ ⇒ “2.1 Assembly overview - toothed belt
aut drive”, page 123
h
ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
3 Valve gear
⇒ “3.1 Assembly overview - valve gear”, page 138
⇒ “3.2 Measuring axial clearance of camshaft”, page 141
⇒ “3.3 Measuring radial clearance of camshafts”, page 142
⇒ “3.4 Removing and installing camshafts”, page 143
⇒ “3.5 Removing and installing camshaft oil seal”, page 149
⇒ “3.6 Checking hydraulic compensation elements”, page 153
⇒ “3.7 Renewing valve stem seals with cylinder head installed”,
page 153
⇒ “3.8 Renewing valve stem seals with cylinder head removed”,
page 157
3.1 Assembly overview - valve gear
Caution
G. Volkswage
Avoid damage to valves and piston
lkswcrowns after working on
agen
A n AG d
oes
not
valve gear. db
y Vo gu
a
e ran
ris tee
utho or
a ac
ss ce
le
un
pt
Note an
d
itte
y li
erm
ab
Cylinder heads with cracks between the valve seats may be used without reducing engine life, provided the
ility
ot p
cracks are small and no more than 0.5 mm wide.

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
Prote AG.

Caddy 2011 ➤
1 - Valve
❑ Must not be machined;
only grinding-in is per‐
missible
❑ Mark installation posi‐
tion for re-installation.
❑ Valve dimensions
⇒ page 163
❑ Checking valve guides
⇒ page 162 .
AG. Volkswagen AG d
agen oes
2 - Cylinder head olksw not
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❑ Observe notes orise nte
⇒ page 123 aut
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❑ Removing and installing s
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e
nl
⇒ page 104
pt
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3 - Valve stem seal
erm
ab
ility
❑ Renewing with cylinder
ot p
wit
head installed
, is n
h re
⇒ page 153 .
hole
spec
❑ Renewing with cylinder
es, in part or in w
head removed
t to the co
⇒ page 157 .
4 - Valve springs
rrectness of i
5 - Valve spring plate
l purpos
6 - Valve cotters
nform
ercia
7 - Cap
m
at
om
io
❑ Removing: With retain‐
n
c
in t
or
ing frame installed,

his
te
pierce one side of cap

a
do
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with an awl and pry out.

p
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en
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❑ Installing: Drive in without sealant using an appropriate thrust piece.

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❑ Drive in depth 1 to 2 mm
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8 - Oil seal co Vo
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Prote AG.
Note
From week 29/12, a modified oil

seal is used; distinguishing charac‐
teristics ⇒ page 149 .
❑ Removing and installing, to 07.12 ⇒ page 149
❑ Removing and installing, from 07.12 ⇒ page 151
9 - Exhaust camshaft
❑ Note various versions
❑ Exhaust camshaft with camshaft restraining wheel ⇒ page 140
❑ Exhaust camshaft without camshaft restraining wheel ⇒ page 140
❑ Measuring axial clearance ⇒ page 141
❑ Measuring radial clearance ⇒ page 142
10 - Bolt
❑ Sequence when loosening ⇒ page 141
3. Valve gear 139

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Caddy 2011 ➤ ir se
d ran
tee
o
4-cylinder diesel aengine
uth (2.0 l engine, common rail) - Edition 09.2016 or
ac
ss
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e
11 - Retaining frame
nl
pt
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❑ With integrated camshaft bearings
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erm
ab
ility
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12 - Inlet camshaft
h re
hole
spec
es, in part or in w
❑ Measuring axial clearance ⇒ page 141
t to the co
❑ Measuring radial clearance ⇒ page 142
13 - Roller rocker fingers
rrectness of i
❑ Mark installation position
l purpos
❑ Check roller bearing for ease of movement.
nform
ercia
❑ Oil contact surface

m
at
om
ion
c
in t
r
14 - Retaining clip
o
his
ate
❑ For hydraulic compensation element.
do
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or
15 - Hydraulic compensation element

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ng
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❑ Checking ⇒ page 153 t. Cop py
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❑ Mark installation position for re-installation.
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❑ Lubricate contact surfaces before installing.
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Exhaust camshaft with camshaft restraining wheel
Exhaust camshaft without camshaft restraining wheel

Caddy 2011 ➤
Sequence when loosening support frame.

– Unscrew bolts of support frame in sequence -24…1-.
Retaining frame - specified torques and installation sequence

1 -1 … 24- Screw in by hand as far as stop
• The retaining frame must make
contact with the cylinder head n over
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t to the co
3.2 Measuring axial clearance of camshaft
rrectness of i
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nf
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orm
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3. Valve gear 141

Caddy 2011 ➤
♦ Dial gauge - VAS 6079-
AG. Volkswagen AG d
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Procedure ss
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un
pt
– Remove retaining frame ⇒ page 143 .
an
d
itte
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rm
ab
– Fasten dial gauge - VAS 6079- to cylinder head with universal
pe
ility
dial gauge bracket - VW 387- as shown in the illustration.
ot
wit
, is n
– Press camshaft against dial gauge by hand.
h re
hole
spec
– Set dial gauge to “0”.
es, in part or in w
t to the co
– Press camshaft away from dial gauge and read off value:
Axial clearance of inlet and outlet camshafts:
rrectness of i
• Specification: 0.048 to 0.118 mm.
l purpos

Torque settings
nform
ercia
♦ ⇒ “3.1 Assembly overview - valve gear”, page 138

m
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tion in
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3.3 Measuring radial clearance of cam‐

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shafts
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Special tools and workshop equipment required Prote
cted AG.
agen
♦ Plastigage
Procedure
– Remove roller rocker finger ⇒ page 143 .
– Remove bearing cap and clean crankshaft journal.
– Place a length of Plastigage corresponding to the width of the
bearing on the journal to be measured or into the bearings.
• The Plastigage must lie in the middle of the bearing.
– Fit retaining frame and tighten.
– Remove retaining frame again ⇒ page 141 .
• Radial clearance: 0.035 to 0.085 mm.
Torque settings

Caddy 2011 ➤
3.4 Removing and installing camshafts

equipment required
♦ Diesel injection pump lock‐
ing pin - 3359-
. Volkswagen AG
gen AG does
♦ Puller - T10052-
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♦ Camshaft
ris fitting
e tool - nte
tho
T40094- eo
au ra
c
ss
♦ Camshaft clamping tool -
ce
le
un
pt
T40095-
an
d
itte
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♦ Camshaft fitting tool -
erm
ab
ility
T40096-
ot p
wit
is n
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ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
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or
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Prote AG.
3. Valve gear 143

Caddy 2011 ➤
♦ Silicone adhesive sealant ⇒ Electronic Parts Catalogue (ET‐

KA)
Removing
– Remove fuel filter ⇒ Fuel supply; Rep. gr. 20 ; Fuel filter;
Removing and installing fuel filter .
– Removed toothed belt from camshaft and high-pressure pump
⇒ page 125 .
– Unscrew and remove bolts -arrows- for toothed belt and cam‐
shaft.
– Remove camshaft sprocket from hub.
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– Counterhold hub with counter-hold tool - T10051- , and loosen

ot
wit
, is n
securing bolt -1- of hub.

h re
hole
spec
– Unscrew hub securing bolt by turning it approx. 2 times.

es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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Prote AG.

Caddy 2011 ➤
– 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 camshaft taper.

– Remove vacuum pump ⇒ page 120 .
– Unscrew retaining frame securing bolts in sequence -24…1-.

– Remove retaining frame.
– Carefully remove camshafts.
Installing
Note
Seal parting surface between retaining frame and cylinder head

using silicone adhesive sealant ⇒ Electronic Parts Catalogue
(ETKA) .
Caution
n AG. Volkswagen AG
The camshafts may be olksinstalled only with the camshaft
wage does
not fitting
tool - T40094- as d described
byV below. The axial bearingsgu in the
ara
retaining frame riswill otherwise be damaged beyond repair
e nteand
tho
the cylinderauhead will have to be renewed.
eo
ra
ss c
ce
le
un
pt
an
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itte
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– Remove sealant residue from cylinder block and retaining

rm
ab
frame using, for example, a plastic rotary brush.

pe
ility
ot
wit
, is n
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Caution
hole
spec
es, in part or in w
Make sure that no sealant residue gets into the cylinder head
t to the co
or the bearings.
rrectness of i
– Clean sealing surfaces. They must be free of oil and grease.

l purpos
– Oil running surfaces of both camshafts.

nform
ercia
Set up camshaft fitting tool - T40094- for camshafts as follows:

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tion in
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Prote AG.
3. Valve gear 145

Caddy 2011 ➤ agen
AG. Volkswagen AG d
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by Vcommon rail) - Edition 09.2016
ol
gu
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ed ran
oris tee
– Remove supports -T40094/3- , -T40094/4-
au
th
and -T40094/5- or
ac
from base plate. Threaded connection
ss is accessible from be‐
ce
le
low.
un
pt
an
d
itte
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rm
ab
pe
Note
ility
ot
wit
, is n
h re
If the supports of the camshaft fitting tool - T40094- are not
hole
spec
marked at present, the removed supports are to be marked, e.g.
es, in part or in w
with number stamps, so they can be fitted in the original positions
t to the co
later.
rrectness of i
l purpos
– Instead, attach supports -T40094/9- and -T40094/10- on outer

positions which have become free.
nform
ercia
– Place support -T40094/2- in position “A” and support -

T40094/1- in position “F”.
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a
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tio
– First insert inlet camshaft as shown. Ensure that indentation
n in
r
-arrow- for cylinder head bolt faces »outwards«.

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Prote AG.
– Apply a 0.50 mm feeler gauge and push support -T40094/8-
into groove of inlet camshaft.
– Now, insert exhaust camshaft and lock in position by means

of its groove -arrow- with -T40094/11- cover.
– Position clamping tool - T40096/1- on exhaust camshaft
gears.
Caution
Ensure that the clamping jaw marked with an arrow is seated

on the wider gear.

Caddy 2011 ➤
– Tighten clamping tool - T40096/1- using knurled wheel so that

faces of gear teeth are in alignment. Use a 13 mm open-jaw
spanner to assist if necessary.
– Slide exhaust camshaft towards inlet camshaft until teeth en‐
gage.
– Position retaining frame on camshafts.
• All camshaft bearings must be seated on the camshafts.
AG. Volkswagen AG d
agen oes
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– Set camshaft fitting toolise- T40095- in place as illustrated in uaran
d b
order to hold camshafts ho in position in retaining frame.
r tee
aut or
ac
– ss
Remove cover - T40094/11- .
ce
le
un
pt
– Pull support - T40094/8- out of inlet camshaft groove.
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Cut off nozzle on tube at front marking (∅ of nozzle approx.
2 mm).
ss
– Apply sealant beads (approx. 2 ... 3 mm wide) -arrows- as
o
cial p
f
shown in diagram to clean sealing surfaces of cylinder head.
inform
mer
atio
m
Caution
o
n
c
i
or
n thi
e
Risk of soiling camshaft bearings due to surplus sealant and

t
sd
va
risk of sealing oil supply bores.

i
o
pr
cum
r
fo
en
ng
♦ Do not apply sealant beads thicker than specified.

t.
yi Co
op py
♦ In area of oil supply bores -arrow- for retaining frame,
t. C rig
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yri
make sure that these are not sealed due to surplus seal‐ p by
o Vo
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ant.
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cted agen
Prote AG.
3. Valve gear 147

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
lksw not
Sealant bead for retaining frame byV
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ed
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– Install new cap ⇒ Item 7 (page 139) flush on cylinder
ut
hor
head. eo
a ra
s c
– Take camshafts out of camshaft fitting tool - sT40095- together
ce
le
with retaining frame and camshaft fitting tool - T40094- .
un
pt
an
d
itte
y li
– Carefully insert camshafts and retaining frame into cylinder
rm
ab
head.
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
tio
– First tighten securing bolts of retaining frame hand-tight in se‐
n in
r
te o
quence -1…24-.
thi
s
iva
do
• The retaining frame should make contact with the cylinder
r
rp
cum
fo
head over the complete surface.
en
ng
t.
yi Co
op
– Tighten retaining frame bolts to final torque in the sequence C py
ht. rig
-1 … 24-. rig ht
py by
co Vo
by lksw
– Remove camshaft fitting tool - T40095- and clamping tool - Prote
cted AG.
agen
T40096/1- .
– Renew camshaft seal ⇒ page 149 .
Caution
Avoid damage to valves and piston crowns after working on

valve gear.
♦ Because hydraulic compensation elements have to settle,
engine must not be started for approx. 30 minutes after
installing camshafts.
♦ Turn the crankshaft carefully at least 2 rotations to ensure
that none of the valves make contact when the starter is
operated.
– Place hub onto camshaft.
– Tighten securing bolt -1- of hub. Use counter-hold tool -

T10051- to do this.

Caddy 2011 ➤
– Push camshaft sprocket onto hub.
Note
The toothed segment -arrow- of the camshaft belt pulley must be

on top.
– Hand tighten securing bolts -1- to camshaft sprocket so that

there is no play.
– Lock hub with locking pin - 3359- .

– Install toothed belt and adjust valve timing ⇒ page 125 .
– Install vacuum pump ⇒ page 120 .
– Install cylinder head cover ⇒ page 117 .
olkswagen AG
en AG. V
– Install fuel filter.
olks
wag does
not
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db ara
– Installorisupplementary
se fuel pump - V393- ⇒ Fuel ntesupply; Rep.
gr.aut20 ; Supplementary fuel pump - V393- ; Removing
h eo
r a and
installing
ss Supplementary fuel pump - V393- . c
ce
e
nl
pt
Torque settings
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
3.5 Removing and installing camshaft oil

seal
rrectness of i
⇒ “3.5.1 Vehicles to 07.12”, page 149

l purpos
⇒ “3.5.2 Vehicles from 07.12”, page 151

nform
ercia
Note
m
at
om
ion
c
From 07.12, a new seal -B- is used, which does not show contin‐
in t
or
uous surface between the camshaft and cylinder head and can
his
ate
do
riv
be identified by a fillet. A different procedure has to be followed

p
cum
here ⇒ page 151 .

for
en
ng
t.
yi Co
Cop py
t. rig
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pyri by
Vo
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cted agen
Prote AG.
3.5.1 Vehicles to 07.12
3. Valve gear 149

Caddy 2011 ➤

equipment required
♦ Fitting tool - 10-203-
♦ Seal puller - T10443-
♦ Torque wrench
(5 … 50 Nm) - V.A.G 1331-
Nm) - V.A.G 1332-
♦ Bolt M12 x 1.5 x 75
AG. Volkswagen AG d
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pt
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pe
ility
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spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
– Removed toothed belt from camshaft and high-pressure pump

com
tio
⇒ page 125 .
n in
r
te o
thi
– Remove camshaft sprocket and hub ⇒ page 143 .

s
iva
do
r
rp
cum
fo
en
g
Caution
n
t.
yi Co
Cop py
ht. rig
If turned too far anti-clockwise, the inner thrust plate becomes rig ht
py by
detached from the pressure screw. In this case, the thrust plate
co Vo
by lksw
cted agen
must be pushed back onto the pressure screw. Prote AG.
– Turn pressure screw of oil seal extractor anti-clockwise »very

carefully« until slight resistance can be felt.

Caddy 2011 ➤
Note
The clamping sleeves of the oil seal extractor are fitted with grub
screws. However, only one of these grub screws -arrow- effects
clamping, the other is fixed.
– Fit oil seal extractor as shown and screw in grub screw -A- to
clamp it in place.
– Screw pressure screw -B- in until oil ring has been pulled out.
Installing
Note
The oil seal sealing lip must not be additionally oiled or greased.
– Remove oil residues from crankshaft journal with a clean cloth.

AG. Volkswagen AG d
agen oes
olksw not
– Fit guide sleeve of fitting tool - 10 - 203- onto camshaftd bas yV gu
ara
shown in illustration. The lettering on the oil seal faces
horise out‐ nte
eo
wards. aut ra
c
ss
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
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
– Press in oil seal with press piece of fitting tool - 10-203- and
bolt M12 × 1.5 x 65 as far as stop. s
– Install camshaft sprocket and hub ⇒ page 143 .
s o
cial p
f in
– Install toothed belt and adjust the valve timing ⇒ page 125 .
form
mer
Torque settings
atio
om
n
c

i
or
n thi
te
sd
a

iv
o
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cum
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3.5.2 Vehicles from 07.12
co lksw
by
cted agen
Prote AG.
3. Valve gear 151

AG. Volkswagen AG d
agen oes
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Caddy 2011 ➤ aut
h
ra
s c
4-cylinder diesel engine (2.0 l engine, common rail) - Edition 09.2016 s
ce
le
un
pt
an
d
♦ Puller - T10443-
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
♦ Assembly tool -T10493-
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.
Removing
– Remove toothed belt from camshaft ⇒ page 125 .
Caution
♦ If unscrewed too far, the internal thrust plate of the puller

-T10443- detaches from the thrust screw. In this case, the
pressure plate must be pressed back on to the thrust bolt.
– Carefully unscrew grub screw -arrow- of puller -T10443- until

a slight resistance is felt.
– Position puller - T10443- such that it is straight, as shown in

illustration, and lock it in place by screwing in grub screw -A-.
– Screw in thrust bolt -B- until oil seal is extracted.
Installing
– Clean contact surface and sealing surface.
Note
The sealing lip of the oil seal must not be additionally oiled or
greased.

AG. Volkswagen AG d
agen oes
o lksw not
y V gu
rise
d b ara
nte Caddy 2011 ➤
autho
4-cylinder diesel engine (2.0 l engine, e ocommon
ra rail) - Edition 09.2016
ss c
ce
e
– Fit guide sleeve -T10493/1- onto camshaft as shown in illus‐
nl
pt
du
tration.
an
itte
y li
erm
ab
– Carefully slide oil seal -1- over guide sleeve onto camshaft.
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
t to the co
The guide sleeve remains on the camshaft as a stop while the oil
seal is being pressed in.
rrectness of i
l purpos
– Press oil seal in onto stop using press tool -T10493/2- and bolt
nform
ercia
-T10493/3- .
m
at
om
– Install toothed belt (adjust valve timing) ⇒ page 125 .
ion
c
in t
or
Torque settings
his
ate
do
riv

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cum
for
en
g

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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co lksw
by
cted agen
Prote AG.
3.6 Checking hydraulic compensation ele‐

ments
Procedure
Note
♦ The hydraulic compensation elements cannot be repaired.

♦ Irregular valve noise during starting is normal.
– Start engine and run until the radiator fan has switched on
once.
– Increase engine speed to approx. 2500 rpm for 2 minutes. If
necessary, perform road test.
If the hydraulic compensation elements are still noisy, determine
the defective compensation element as follows:
– Turn crankshaft by the bolt for the toothed belt wheel until cam
of supporting element to be tested is facing upwards.
– Press roller rocker finger downwards -arrow- to check clear‐
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 Renewing valve stem seals with cylinder

head installed
3. Valve gear 153

Caddy 2011 ➤
♦ Valve stem seal puller - 3364-
♦ Valve stem seal fitting tool - 3365-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
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♦ Dismantling and assembling device for valve cotters - VAS s
ce
le
5161 A-
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
Procedure
nform
ercia
– Remove all glow plugs ⇒ page 374 .

m
a
com
tio
– Remove camshafts ⇒ page 143 .

n in
r
te o
thi
– Mark allocation of roller rocker fingers and hydraulic compen‐

s
iva
do
sation elements for reinstallation.

r
rp
cum
fo
– Remove roller rocker fingers together with hydraulic compen‐

en
ng
t.
yi Co
sation elements and place down on a clean surface. t. Cop py
rig
gh ht
– Set piston of respective cylinder to “bottom dead centre”. yri
p by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Place guide plate -VAS 5161/23- onto cylinder head.

– Tighten guide plate on intake manifold side by hand using
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
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
– Screw sealing pins -VAS 5161/10- into guide plate.
y li
rm
ab
pe
– Screw adapter -VAS 5161/11- hand-tight into relevant glow
ility
ot
plug thread.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
– Insert drift -VAS 5161/3- into guide plate and use a plastic
m
a
hammer to knock loose the firmly seated valve cotters.
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
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pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Connect adapter to compressed air supply using a commer‐
cially available union and apply pressure continuously.
• Minimum pressure: 6 bar.
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge together with spacer.
– Remove valve spring and valve spring plate.
3. Valve gear 155

Caddy 2011 ➤
– Pull off valve stem seal using valve stem seal puller - 3364- .
Caution
Risk of damage when installing valve stem seals.
Note n AG. Volkswagen AG do

lkswage es n
o ot g
yV
A plastic sleeve -A- is included with the new valvesestem
d b oil seals. ua
ran
ir tee
tho
u or
a ac
– Fit plastic sleeve -A- onto valve stem to sprevent
s damage to
new valve stem oil seal -B-.
ce
e
nl
pt
du
an
itte
– Lightly oil sealing lip of valve stem seal.
y li
erm
ab
– Push valve stem oil seal onto plastic sleeve.
ility
ot p
wit
, is n
– Carefully press valve stem oil seal onto valve guide using
h re
hole
valve stem seal fitting tool - 3365- .
spec
es, in part or in w
– Remove plastic sleeve.
t to the co
– If valve cotters have been removed from assembly cartridge ,
they need to be put into insertion device - VAS 5161/18- first.
rrectness of i
• Larger diameter of valve cotters faces upwards.
l purpos
– Insert valve spring and valve spring plate.
nform
ercia
– Press assembly cartridge onto valve cotter insertion device

from above and pick up valve cotters.
m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
– Insert assembly cartridge - VAS 5161/8- into guide plate -

VAS 5161/23- again.
– Press pressure fork downwards and pull
n AG. Voknurled screw
lkswagen AG do up‐
wards, turning it clockwiseVand wage
olks anticlockwise. This inserts
es n the
ot g
valve cotters. ed by ua
ra
is nte
or
– Reduce pressureaon
ut pressure fork whilst pulling on knurled
h eo
ra
screw. ss c
ce
e
nl
pt
– Repeat procedure on each valve.
du
an
itte
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Installing
erm
ab
ility
ot p
wit
, is n
h re
– Ensure that all roller rocker fingers contact valve stem ends
hole
spec
correctly and are clipped into relevant hydraulic compensation
es, in part or in w
elements.
t to the co
– Install camshafts ⇒ page 143 .
rrectness of i
– Install glow plugs ⇒ page 374 .
l purpos
Torque settings
nf
ercia
o
rm
m
atio
m

o
n in
or c
thi
te
3.8 Renewing valve stem seals with cylinder

sd
iva
o
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rp
head removed cu
o
m
f
en
ng
t.
yi Co
op
Special tools and workshop equipment required C py
t. rig
gh ht
yri by
♦ Valve stem seal puller - 3364- op Vo
by c lksw
cted agen
Prote AG.
♦ Valve stem seal fitting tool - 3365-
3. Valve gear 157

Caddy 2011 ➤
AG. Volkswagen AG d
agen o
♦ Dismantling and assembling
olks device for valve cotters s-nVAS
w e
ot g
yV
5161 A- sed b ua
ran
ri tee
ho
aut or
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
♦ Engine and gearbox support - VAS 6095A-
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
♦ Cylinder head tensioning device - VAS 6419-
by lksw
cted agen
Prote AG.
Removing
– Remove camshafts ⇒ page 143 .
– 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- .

Caddy 2011 ➤
– Tension cylinder head on cylinder head tensioning device as

AG. Volkswagen AG d
shown in illustration.
lkswagen oes
n o ot g
yV u
– Connect rcylinder
ise
db head tensioning device to compressed
ara
nte air.
tho eo
– Use lever
au -arrow- to slide air cushion under combustionr cham‐
ac
ss
ber from which valve stem seal is to be removed.
ce
e
nl
pt
du
– Allow compressed air to flow into air cushion until it lies against
an
itte
y li
valve disc.
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
– Place guide plate -VAS 5161/23- onto cylinder head.
– Tighten guide plate on intake manifold side by hand using
rrectness of i
knurled screw -VAS 5161/12- and 2 M6x30 bolts -item 1- until
it makes contact.
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
op
– Insert drift -VAS 5161/3- into guide plate and use a plastic C py
t. rig
hammer to knock loose the firmly seated valve cotters.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Screw toothed piece -VAS 5161/6- with hooking fork -

VAS 5161/5- into guide plate.
– Push sleeve -VAS 5161/23-1- onto assembly cartridge -
VAS 5161/8- .
– Attach pressure fork -VAS 5161/2- to toothed piece and press
assembly cartridge down.
– At the same time, turn knurled screw of assembly cartridge
clockwise until tips engage in valve cotters.
– Move knurled screw back and forth to press apart valve cotters
and capture them in assembly cartridge.
– Release pressure fork.
– Remove assembly cartridge together with spacer.
– Remove valve spring and valve spring plate.
3. Valve gear 159

Caddy 2011 ➤
– Pull off valve stem seal using valve stem seal puller - 3364- .
Caution
Risk of damage when installing valve stem seals.
AG. Volkswagen AG d
agen oes
olksw not
yV gu
Note rised b ara
nte
ho eo
aut ra
A plastic sleeve
ss -A- is included with the new valve stem oil seals.c
ce
le
un
pt
an
d
– Fit plastic sleeve -A- onto valve stem to prevent damage to

itte
y li
new valve stem oil seal -B-.
rm
ab
pe
ility
ot
– Lightly oil sealing lip of valve stem seal.
wit
, is n
h re
– Push valve stem oil seal onto plastic sleeve.
hole
spec
es, in part or in w
– Carefully press valve stem oil seal onto valve guide using
valve stem seal fitting tool - 3365- . t to the co
– Remove plastic sleeve.

rrectness of i
– If valve cotters have been removed from assembly cartridge ,

l purpos
they need to be put into insertion device - VAS 5161/18- first.

• Larger diameter of valve cotters faces upwards.
nform
ercia
– Insert valve spring and valve spring plate.

m
a
com
tion in
– Press assembly cartridge onto valve cotter insertion device

r
te o
from above and pick up valve cotters.

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 ➤
– Insert assembly cartridge - VAS 5161/8- into guide plate -

VAS 5161/23- again.
– Press pressure fork downwards and pull knurled screw up‐
wards, turning it clockwise and anticlockwise. This inserts the
valve cotters.
– Reduce pressure on pressure fork whilst pulling
AG. Volkswon
ageknurled
n AG d
agen
screw. Volksw
oes
not
g y ua
db ran
– Repeat procedure on each
or valve.
ise tee
th or
au
Installing ss
ac
ce
e
nl
pt
du
an
itte
y li
– Ensure that all roller rocker fingers contact valve stem ends
erm
ab
correctly and are clipped into relevant hydraulic compensation
ility
ot p
elements.
wit
, is n
h re
– Install camshafts ⇒ page 143 .
hole
spec
es, in part or in w
Torque settings
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.
3. Valve gear 161

Caddy 2011 ➤
4 Inlet and exhaust valves

⇒ “4.1 Reworking valve seats”, page 162
⇒ “4.2 Checking valve guides”, page 162
⇒ “4.3 Checking valves”, page 163
⇒ “4.4 Valve dimensions”, page 163
4.1 Reworking valve seats
Note
. Volkswagen AG
gen AG does
swa
Valve seats must not be reworked due to the very narrow toler‐ y Volk not
gu
ances. risedb ara
nte
ho eo
aut ra
4.2 Checking valve guides ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
♦ Dial gauge - VAS 6079-
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Test sequence
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 theAG
guide.
. Volkswagen
agen AG do
ksw es n
– Determine rock. by Vol ot g
ua
ed ran
• Wear limit: 1.0 mm. oris tee
th or
au ac
– If the wear limit is exceeded,ssrepeat the measurement with
ce
le
new valves.
un
pt
an
d
itte
– Renew cylinder head if wear limit is still exceeded.
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
Valve guides cannot be exchanged.
t to the co
4.3 Checking valves
rrectne
– Check for scoring on valve stems and valve seat surfaces.
ss
– Exchange valve if significant scoring can be seen.
o
cial p
f inform
4.4 Valve dimensions
mer
atio
om
n
c
i
or
Note
thi
te
sd
iva
o
pr
Inlet and exhaust valves must not be reworked. Only lapping-in

um
r
fo
en
is permitted.
ng
t.
yi Co
Cop py
t. rig
gh ht
Dimension Inlet valve Outlet valve
pyri by
Vo
co lksw
by
cted
∅a mm 28.10 26.00
agen
Prote AG.
b mm 99.30 99.10
Diameter mm 5.975 5.965
c
d ∠° 45 45
4. Inlet and exhaust valves 163

Caddy 2011 ➤
17 – Lubrication
1 Sump, oil pump
⇒ “1.1 Assembly overview - sump/oil pump”, page 164
⇒ “1.2 Removing and installing oil pan”, page 166
⇒ “1.3 Removing and installing oil pump”, page 170
⇒ “1.4 Removing and installing oil pump, with balancer shaft mod‐
ule”, page 171
⇒ “1.5 Engine oil:”, page 172
⇒ “1.6 Removing and installing oil level and oil temperature send‐
er G266 ”, page 172
1.1 Assembly overview - sump/oil pump
1 - Bolt
❑ 15 Nm
2 - Sealing flange
❑ With seal
❑ Must seat on dowel
sleeves.
❑ Insert with silicone seal‐
ant ⇒ Electronic Parts
Catalogue (ETKA) .
❑ Do not additionally oil or AG. Volkswagen AG d
agen
grease the oil seal seal‐ olksw
oes
not
ing lip. byV gu
ara
ed
ris nte
❑ Before installing, re‐ ut
ho eo
ra
move oil residue from ss a c
crankshaft journal using
ce
le
un
pt
a clean cloth.
an
d
itte
y li
❑ Renewing crankshaft oil
erm
ab
seal - belt pulley end
ility
ot p
⇒ page 73
wit
is n
h re
ole,
spec
⇒ page 69
t to the co
3 - Toothed belt for oil pump
❑ Check for damage and
wear.
rrectne
❑ Renew if necessary.
ss
Note
o
cial p
f inform
♦ Belts which have been in use

mer
atio
longer can sag.

om
n
c
♦ This is not a fault and does not

or
n thi
e
necessarily mean belt needs re‐

t
sd
va
placing.
i
o
pr
cum
r
fo
en
ng
t.
yi
4 - Bolt
Co
Cop py
. rig
❑ 10 Nm
ht ht
rig by
copy Vo
lksw
5 - Oil dipstick
by
cted agen
Prote AG.
❑ The oil level must not be above the max. mark!
❑ Markings ⇒ page 172 .
164 Rep. gr.17 - Lubrication

Caddy 2011 ➤
6 - Guide tube
7 - Clip
8 - Dowel sleeves
9 - O-ring
10 - Bolt n AG. Volkswagen AG do
wage es n
❑ 10 Nm yV
olks ot g
ua
b
ed ran
11 - Oil pump with pressed-on toothed
horis belt pulley tee
ut or
❑ With 12 bar pressure relief
ss
a valve ac
ce
e
❑ Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.
nl
pt
du
an
itte
If toothed belt or oil pump have to be removed:
y li
erm
ab
♦ Check oil pump for free movement
ility
ot p
wit
♦ It should be possible to turn toothed belt sprocket easily with 1 finger.
, is n
h re
hole
♦ Replace if difficult to turn.
spec
es, in part or in w
12 - Suction line
t to the co
❑ Clean strainer if soiled
13 - Baffle plate
rrectness of i
14 - Bolt
l purpos
❑ 15 Nm
nform
ercia
15 - Oil pan
m
❑ Clean sealing surface before fitting.
at
om
io
❑ Install with silicone sealant ⇒ Electronic Parts Catalogue (ETKA) .
n
c
in t
or
his
e

at
do
priv
16 - Bolt
um
for
en
g

n
t.
yi Co
Cop py
.
17 - Spreader clip
t rig
gh ht
pyri by
Vo
❑ Only vehicles with cover for oil sump
co lksw
by
cted agen
Prote
❑ Large
AG.
18 - Spreader clip
❑ Only vehicles with cover for oil sump
❑ Small
19 - Cover for oil sump
❑ Not fitted in all vehicles
20 - Bolt
❑ 10 Nm
21 - Oil level and oil temperature sender - G266-
❑ Black 3-pin connector
22 - Sealing ring
23 - Oil level and oil temperature sender - G266- wiring harness
24 - Oil drain plug
❑ 30 Nm
1. Sump, oil pump 165

Caddy 2011 ➤
25 - Sealing ring
26 - Bolt
❑ 15 Nm
27 - Bolt
❑ Insert without sealant.
❑ 27 Nm
28 - Oil spray jet
Sump - specified torque and tightening sequence

1 -1 to 20- In diagonal sequence to 5 Nm
2 -Arrows- 40 Nm
13 Nm
AG. Volkswagen AG d
agen
1.2 Removing and installing oil pan y Volksw
oes
not
gu
d b ara
Special tools and workshop equipment required rise nte
tho eo
au ra
♦ Torque wrench - V.A.G 1331- ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ T-bar and socket, 10 mm - 3185-

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 ➤
4-cylinder diesel engine (2.0gel nengine,
AG. Volkscommon
wagen AG rail) - Edition 09.2016
d wa oes
olks not
yV gu
♦ Torx bit T40 - T10058- ed
b ara
nte
ris
tho eo
au ra
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
rrectne
Removing
s
– Drain engine oil ⇒ Maintenance ; Booklet 39 .
s o
cial p
f i
– Loosen clamps -1 - and -2- and remove connecting hose.
nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
– Unscrew bolts -arrows-. Prote AG.
– Free coolant hose -3-.

– Release hose clip -2-.
– Disconnect electrical connector -1- on charge pressure sender
- G31- and remove right air pipe.
– Unscrew bolt -arrow- and push coolant circulation pump 2 -

V178- to the side.

Caddy 2011 ➤
– Unscrew bolt -arrow- on left air pipe.
– Disconnect electrical connector -arrow- on oil level and oil

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
erm
ab
ility
ot p
wit
is n
– If fitted, remove noise insulation -1- for sump. To do this, re‐
h re
ole,
lease fasteners -arrows-.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
– Unscrew bolts -arrows- of sump to gearbox connection.

te
sd
iva
o
pr
– Slacken bolts -1 … 20- in diagonal sequence and remove.

um
r
fo
en
ng
t.
– Release oil sump carefully from adhesive.
yi Co
Cop py
ht. rig
– Loosen sump with light blows of a rubber headed hammer if rig ht
py by
necessary.
co Vo
by lksw
cted agen
Prote AG.
– Remove sealant remaining on crankcase with flat scraper.

Caddy 2011 ➤
Installing
Caution
Danger of soiling lubrication system and bearings.

♦ Cover open parts of engine.
♦ Wear safety goggles.
♦ Do not apply sealant bead thicker than specified.
– Remove sealant residue from bottom section of sump -1- us‐

ing a rotating plastic brush, for example.
– Clean sealing surfaces; they must be oil and grease free.
Use sealant as per ⇒ Electronic Parts Catalogue (ETKA) .
Note
AG. Volkswagen AG d
agen oes
Observe use-by-date of sealant. Volksw not
gu
d by ara
ise nte
r
– Cut off nozzle on tube at frontaut marking (∅ of nozzle approx.
ho eo
ra
2 mm). ss c
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

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

illustrated.
• Thickness of sealant bead: 2…3 mm.
Note
♦ Take particular care when applying sealant bead -arrows- in

area of rear sealing flange.
♦ The sump must be installed within 5 minutesVafter
olkswa
sealant is
applied. wage
n AG. gen AG
does
Volks not
gu
♦ When installing sump with engine
ise
d by
removed, ensure that sump ara
nte
is flush with crankcase atth flywheel end.
o r eo
au ra
♦ Allow sealant to dry for approx. 30 minutes after installing
ss c
ce
e
sump. Only then fill with engine oil.

nl
pt
du
an
itte
y li
erm
ab
– Place oil sump in position and slightly tighten the sump--to-
ility
ot p
gearbox connecting bolts and all the oil sump bolts. Ensure
wit
that sump is flush against intermediate plate and gearbox
, is n
h re
flange.
hole
spec
– Install coolant circulation pump 2 - V178- .
es, in part or in w
t to the co
– Install air pipes ⇒ page 239 .
rrectness of i
l purpos
– Replenish engine oil and check oil level.

Torque settings
nf
ercia
or
m
m
atio
om
♦ Noise insulation; Assembly overview - noise insulation ⇒ Rep.

n in
or c
gr. 66 ; Assembly overview - noise insulation

thi
te
sd
iva
o
r
rp
cu
1.3 Removing and installing oil pump

o
m
f
en
ng
t.
yi Co
op
Removing C py
t. rig
gh ht
yri by
– Remove sump ⇒ page 166 . cop Vo
by lksw
cted agen
Prote
– When oil pump is to be renewed, unscrew bolts -4- and remove
AG.
oil intake pipe -3-.

– Unscrew bolts -arrows- and remove baffle -2-.
– Detach oil pump -1- from toothed belt and remove pump.
Installing
Note
♦ If oil pump does not move easily, it must be renewed.

♦ A damaged toothed belt must be renewed.
♦ The toothed belt can sag after long use, this is not a fault.
– Renew O-ring.

Caddy 2011 ➤
– Insert new dowel sleeves when oil pump has no dowel sleeves
-arrows- for centring oil pump.
– Check oil pump for ease of movement, turn toothed belt pulley
with one finger for this.
– Check toothed belt for oil pump.
– Fit oil pump with toothed belt pulley into toothed belt and tight‐
en along with baffle.
– Replenish engine oil and check oil level ⇒ page 164 .
Torque settings
AG. Volkswagen AG d
♦ ⇒ “1.1 Assembly overview - sump/oillkpump”,
swa
gen page 164 oes
not
o
yV gu
edb ara
s nte
1.4 Removing and installing oil pump, with aut
ho
ri eo
ra
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♦ Circlip pliers (commercially available)
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Removing
spec
t to the co
– Unscrew bolts -arrows- and pull suction line off oil pump.
rrectness o
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– Remove circlip -1- with circlip pliers.
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– Pull drive shaft -2- out of oil pump using a magnet -arrow-.
c by lksw
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– Unscrew bolts -3, 4, 5- and remove oil pump.
Caution
Bolt on intermediate gear wheel must not be loosened.
Installing
Note
♦ Renew O-ring.
♦ Renew circlip.
♦ The retaining ring must seat in the base of the groove.

Caddy 2011 ➤
– Insert dowel sleeves if oil pump has no dowel sleeves

-arrows-.
– Insert dowel sleeves if balancer shaft module has no dowel
sleeves for centring oil pump.
Torque settings
page 187
1.5 Engine oil:
Note
The oil level may be in area -d- due to the infiltration of fuel in the
engine oil as a result of unfavourable driving conditions after fill‐
ing. This is a perfectly normal and self-regulating characteristic.
It is not necessary to adjust the engine oil level.
1 - Min. mark
2 - Max. mark
a - Oil level in min. mark area: replenish engine oil!
b - Oil level in middle range: can be topped-up with engine oil.
c - Oil level in max. mark area: Do not replenish engine oil!
wage es n
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The oil level must remain below the max. mark - danger of dam‐
erm
ab
age to catalytic converter! Markings

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1.6 Removing and installing oil level and oil

spec
temperature sender - G266-

t to the co
Removing
rrectne
– Drain engine oil ⇒ Maintenance ; Booklet 39 .

– Disconnect electrical connector -arrow- on oil level and oil
ss

o
cial p
f inform
mer
atio
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n
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te
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Prote AG.

Caddy 2011 ➤
en AG. Vcommon
olkswagen rail)
AG - Edition 09.2016
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– If fitted, remove noise insulation -1- for sump. Toedo d b this, re‐
y ara
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lease fasteners -arrows-. thoris eo
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spec
t to the co
rrectne
– Unscrew bolts -2-.
– Remove oil level and oil temperature sender - G266- -1-.
ss o
cial p
Installing
f inform
mer
atio
m
– Replenish engine oil and check oil level ⇒ Maintenance ;

o
n
c
i
or
n
Booklet 39 .
thi
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Torque settings
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♦ ⇒ page 164
en
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Caddy 2011 ➤
2 Oil filter, oil pressure switch n AG. Volkswagen AG do

lkswage es n
⇒ “2.1 Assembly overview - oil filter housing with engine d byoil
Vo cool‐ ot g
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er”, page 174 o
ir se
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⇒ “2.2 Removing and installing oil filter housingsswith engine oil
a ac
cooler”, page 175
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nl
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⇒ “2.3 Removing and installing oil pressure switch F1 ”,
itte
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page 179
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⇒ “2.4 Checking oil pressure switch F1 ”, page 180
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⇒ “2.5 Checking oil pressure”, page 181
hole
spec
es, in part or in w
⇒ “2.6 Measuring oil consumption”, page 182
t to the co
2.1 Assembly overview - oil filter housing
with engine oil cooler
rrectness of i
l purpos
Caution
nform
ercia
Seals ⇒ Item 11 (page 175) and ⇒ Item 14 (page 175) must

not be lubricated with oil. The coolant seals would otherwise
m
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swell up.
on
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1 - O-ring
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2 - Cap
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❑ 25 Nm
agen
Prote AG.
3 - O-ring
4 - O-ring
5 - Oil filter element
❑ Observe change inter‐
vals ⇒ Maintenance ;
Booklet 39 ; Proce‐
dures .
6 - Guide tube
❑ Renew O-ring after
each removal
7 - Bolt
❑ 10 Nm
8 - Spreader clip
9 - Engine oil cooler
❑ Ensure clearance to ad‐
jacent components
❑ Renew coolant after re‐
placing.
❑ Connection diagram for
coolant hoses
⇒ page 204
❑ Checking engine oil
cooler for leaks
⇒ page 214

Caddy 2011 ➤
10 - Bolt
❑ 11 Nm
11 - Rubber seals AG. Volkswagen AG d
agen oes
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❑ Renew after removal byV
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❑ May not be lubricated with oil horis nte
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❑ Fit into lugs on engine oil cooler ss a ra
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12 - Bolt
un
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❑ Tightening sequence ⇒ page 175
pe
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❑ 14 Nm +180°
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13 - Oil filter bracket
spec
es, in part or in w
❑ Ensure clearance to adjacent components
t to the co
❑ With integrated oil non-return
rrectness of i
14 - Rubber seals
l purpos

❑ May not be lubricated with oil
nform
ercia
❑ Fit into lugs on oil filter bracket.

m
a
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tion in
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te o
thi
Tightening sequence for oil filter bracket
s
iva
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rp
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– First, tighten new upper left and lower right bolts.
um
fo
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Cop py
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Prote AG.
2.2 Removing and installing oil filter housing

with engine oil cooler
2. Oil filter, oil pressure switch 175

Caddy 2011 ➤
olkswagen AG
en AG. V
♦ Removal lever - 80 -ol200-
ksw
ag does
not
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tho eo
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♦ Used oil collection and extraction unit - V.A.G 1782-
rrectness o
cial p
f inform
mer
atio
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n
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♦ Drip tray for workshop hoist - VAS 6208-
o Vo
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Prote AG.
Removing
– Remove radiator cowl ⇒ page 226 .

Caddy 2011 ➤
– Remove oil filter element ⇒ Maintenance ; Booklet 39 .
– Loosen hose clamps -1- and -2- and remove air hose. lkswage es n
o ot g
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t to the co
rrectne
– Lay coolant hose -3- to one side.
s
s o
cial p
f i
nform
- G31- / intake air temperature sender - G42- and remove right
mer
atio
air pipe.
om
n
c
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or
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fo
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Cop py
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Prote AG.

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.
– Place drip tray for workshop hoist - VAS 6208- under coupling
point.
lkswage es n
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– Remove coolant hose -4-, loosening hose clip -3- to do so.
rm
ab
pe
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– Place used oil collection and extraction unit - V.A.G 1782- un‐
wit
, is n
der engine.
h re
hole
spec
– Unscrew bolts -2- and remove oil filter bracket together with
es, in part or in w
engine oil cooler.
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia
♦ Renew gaskets, seals and O-rings.

m
a
com
tio
n in

r
te o
thi
s
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to original equipment ⇒ ETKA (Electronic Parts Catalogue) .

fo
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t.
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– Bolt on oil filter bracket hand-tight in the sequence -1 … 4-.
gh ht
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– Tighten bolts in the sequence -1 … 4-. cted agen
Prote AG.
– Install dipstick guide tube ⇒ page 174 .

– Install charge air pipe ⇒ page 239 .
– Installing intake hoses with screw-type clips ⇒ page 241 .
– Install radiator cowl ⇒ page 226 .
– Replenish coolant in cooling system, change coolant if engine
oil cooler has been renewed ⇒ page 207 .
Torque settings
♦ ⇒ “2.1 Assembly overview - oil filter housing with engine oil
cooler”, page 174

Caddy 2011 ➤
2.3 Removing and installing oil pressure

switch - F1-
♦ Hose clamp pliers - VAS 6340-
AG. Volkswagen AG d
agen oes
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– Press release buttons and remove hose -1- for venting crank‐
ility
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case.
wit
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– Unclip vacuum lines -arrows- and place to one side.

hole
spec
es, in part or in w
– Unscrew bolt -2- (captive bolt). Twist intake hose -3- clockwise
t to the co
out of its holder and remove.

rrectness of i
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nf
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orm
m
atio
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– Unscrew bolts -2- and -3-, remove engine lifting eyes -1-.
o
n in
or c
– Disconnect electrical connector -arrow-.

thi
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– Remove oil pressure switch - F1- .

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– Fit gasket.
by lksw
cted agen
Prote AG.
– Install vacuum line to exhaust gas recirculation cooler
⇒ page 369 .

Caddy 2011 ➤

– Install intake pipe ⇒ page 249 .
Torque settings
2.4 Checking oil pressure switch - F1-

equipment required
♦ Oil pressure tester - V.A.G
1342-
AG. Volkswagen AG d
♦ Voltage tester - V.A.G agen oes
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1594 C- ss c
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cial p
f inform
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t.
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Cop py
t. rig
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pyri by
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by c lksw
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Prote AG.
Test conditions
• Oil level OK, checking ⇒ page 172
• 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 179 .

– 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
Observe oil pressure tester and LED n while

AG. Volstarting,
kswagen AGasdoswitching
point of oil pressure switch - VF1- wage
olks may already be exceeded
es n when
ot g
starting. sed by ua
ran
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– Start engine and
ss increase
a
revolutions slowly. ac
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nl
• LED should light up at 0.3…0.6 bar.

pt
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– If LED does not light up, renew oil pressure switch - F1-
erm
ab
⇒ page 179 .
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Torque settings
h re
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spec

es, in part or in w
t to the co
2.5 Checking oil pressure

rrectness of i

l purpos
♦ Oil pressure tester - V.A.G 1342-

nform
mercia
at
om
ion
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or
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ate
do
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for
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t.
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Cop py
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Prote AG.
Test conditions
• Oil level OK, checking ⇒ page 172

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

run once)
Test sequence
– Remove oil pressure switch - F1- ⇒ page 179 .
– 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. agen
AG. Volkswagen AG d
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• Oil pressure at idling speed: at least 0.6 bar ed by ara
nte
ris
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• Minimum oil pressure at 2,000 rpm: at least aut 1.0 bar
h
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2.6 Measuring oil consumption
ce
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♦ Vehicle diagnostic tester
wit
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Procedure
ole,
spec
– Apply handbrake.
t to the co
– Manual gearbox: gear lever in neutral.
– Automatic gearbox: move selector lever to position “N”.
rrectne
– Connect ⇒ Vehicle diagnostic tester.
s
– Switch on ignition.
s o
cial p
f in
– Carry out program Oil consumption measurement using
form
mer
⇒ Vehicle diagnostic tester and follow instructions.
atio
om
n
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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 ➤
3 Engine oil cooler

⇒ “3.1 Removing and installing engine oil cooler”, page 183
3.1 Removing and installing engine oil cool‐

er
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
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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
l purpos
nform
mercia
at
om
ion
c
in t
or
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ate
do
riv

p
cum
for
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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.
3. Engine oil cooler 183

Caddy 2011 ➤
Removing
– Open air intake cover. To do this, carefully release the catches
-arrows-.
– Unscrew bolts -arrows- for air intake -1- and take connecting
hose -2- out of guide.
– Press in locking lugs -1- and -3- and pull connecting hose -4- en AG. Volkswagen AG
off air filter housing -2-. olks
wag does
no
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db ara
– Remove air filter housing ⇒ page 341 . rise nte
tho eo
– Remove radiator cowl ⇒ page 226 . au ra
c
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
– In addition to draining coolant from engine, pull coolant hose

from oil filter holder -arrow-.
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Remove oil filter element.
lkswage es n
o ot g
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d ran
ir se tee
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a ac
ss
ce
e
nl
pt
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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
– Remove engine oil cooler from housing.
l purpos
Installing
nf
ercia
orm
m
atio
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n in
c
Note
or
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sd
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op
oil and grease before installation. C py
t. rig
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♦ Secure all hose connections with the hose clips corresponding cop Vo
by lksw
to original equipment ⇒ ETKA (Electronic Parts Catalogue) . cted agen
Prote AG.
– Insert new seals ⇒ Item 11 (page 175) into oil free lugs
-arrow- on oil filter bracket.
– Carefully slide engine oil cooler onto centring pins.
3. Engine oil cooler 185

Caddy 2011 ➤ AG. Volkswagen G d
agen(2.0 l engine, A
4-cylinder diesel oengine common no rail) - Edition 09.2016
oes
V lksw t gu
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– Press oil coolerthoon until it is flush -1- with end of centring pins.
ris
eo
au ra
– Start new bolts, and screw them in until heads make contact. c
ss
ce
e
nl
pt
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Tighten bolts -arrows- alternately in diagonal sequence in 3
l purpos
steps.
– Replenish coolant in cooling system, change coolant if engine
nform
ercia
oil cooler has been renewed ⇒ page 207 .

m
at
Torque settings
om
ion
c
in t
r
♦ ⇒ “2.1 Assembly overview - oil filter housing with engine oil

o
his
te
cooler”, page 174

a
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cum
for
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ng
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Cop py
t. rig
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co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
4 Balancer shaft module

⇒ “4.1 Assembly overview - balancer shaft module”, page 187
⇒ “4.2 Removing balancer shaft module”, page 190
⇒ “4.3 Installing a new balancer shaft module”, page 192
⇒ “4.4 Installing a previously used balancer shaft module again”,
page 196
4.1 Assembly overview - balancer shaft module

AG. Volkswagen AG d
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1 - Sealing ring ed by
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❑ Permanently attached
ut
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to drain plug
ss a ra
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2 - Oil drain plug

nl
pt
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an
itte
❑ 30 Nm
y li
erm
ab
ility
3 - Oil pan
ot p
wit
, is n
h re
⇒ page 166
hole
spec
es, in part or in w
4 - Bolt
t to the co
❑ 9 Nm
5 - Suction line
rrectness of i
❑ Clean strainer if soiled
l purpos
6 - O-ring
❑ Renew after removal nform
ercia
7 - Oil pump
m
at
om
❑ Before installing, check

on
c
in t
that the two dowel

or
his
e
sleeves for centring oil

at
do
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pump on balancer shaft

p
cum
or
module are fitted

f
en
ng
t.
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Co
Cop py
⇒ page 171
t. rig
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pyri by
Vo
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8 - Input shaft by c lksw
cted agen
Prote AG.
❑ For oil pump
9 - Retaining ring
❑ Must lie in base of
groove
❑ Renew damaged or
over-tensioned circlip
10 - Spur gear
❑ For balancer shaft
11 - Bolt
❑ 20 Nm +90°
12 - Thrust washer
❑ For intermediate gear wheel
❑ To install intermediate gear wheel, secure to balancer shaft module with grease
❑ Fitting position ⇒ page 189
4. Balancer shaft module 187

AG. Volkswagen AG d
agen oes
olksw not
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Caddy 2011 ➤ thor eo
u ra
4-cylinder diesel engine (2.0 sls engine,
a common rail) - Edition 09.2016 c
ce
e
nl
pt
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13 - Intermediate gear
an
itte
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erm
ab
ility
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❑ A coating is applied to the new intermediate gear wheel which sets the correct tooth backlash through
wit
, is n
wear
h re
hole
❑ Installation position: Part number must be visible.
spec
❑ Make sure thrust washer is seated correctly ⇒ page 189 es, in part or in w
t to the co
14 - Bolt
rrectness of i
❑ With washer
l purpos
❑ 90 Nm +90°
15 - Hub
nform
ercia

m
at
om
❑ For intermediate gear wheel
ion
c
in t
or
16 - Crankshaft sprocket
his
ate
do
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17 - Balancer shaft module

p
cum
for
❑ Before installing, check that the two dowel sleeves for centring balancer shaft module on cylinder block
en
ng
t.
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are fitted. t. Cop py
rig
❑ Removing ⇒ page 190
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pyri by
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co
❑ Reinstalling previously run balancer shaft module ⇒ page 196
by lksw
cted agen
Prote AG.
❑ Installing new balancer shaft module ⇒ page 192
18 - Bolt
19 - Dowel sleeves
20 - Bolt
❑ 9 Nm
21 - Oil extraction pipe
22 - Bolt
❑ 9 Nm
23 - Spreader clip
❑ Large
24 - Spreader clip
❑ Small
25 - Noise insulation for oil sump
26 - Bolt
❑ Self-locking
❑ 9 Nm
27 - Oil level and oil temperature sender - G266-
28 - Sealing ring
29 - Bolt

Caddy 2011 ➤
Sump - specified torque and tightening sequence

1 -1 to 20- In diagonal sequence to 5 Nm
2 -Arrows- 40 Nm
15 Nm
Thrust washer installation position
Caution
olkswagen AG
en AG. V
Risk of thrust washer slipping behind intermediate gear Vwheel.
olks
wag does
not
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♦ When installing intermediate gear wheel, make or
isesure that nte
thrust washer -A- does not slip out of balancer
au
th shaft mod‐ eo
ra
ule indentations -arrows- and subsequentlyss become jam‐ c
med. If necessary, fix in place with grease on balancer
ce
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nl
pt
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shaft module.
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Balancer shaft module - specified torques and sequence
hole
spec
es, in part or in w
t to the co
rrectness of i
2 -1 to 8- 6 Nm
l purpos
3 -5- and -7- 13 Nm

4 -1, 2, 3, 4, 6, 8- 20 Nm
nform
ercia

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ion
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en
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by lksw
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Prote AG.

Caddy 2011 ➤
– Tighten bolts of balancer shaft module at 6 securing points as

follows:
1 -1 to 6- Hand-tighten in sequence
2 -1 to 6- Initially tighten bolts in sequence to
6 Nm AG. Volkswagen AG d
agen oes
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3 -1 … 4- by V Tighten to 20 Nm.
ol not
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4 -5 and rise6- Tighten to 13 Nm nte
tho eo
u ra
5 ss-1
a to 6- Turn bolts 90° further in sequence us‐ c
ing a fixed wrench
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le
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pt
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pe
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es, in part or in w
t to the co
4.2 Removing balancer shaft module
rrectness of i
l purpos

nform
mercia
a
com
tion in
r
te o
thi
s
iva
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t.
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Cop py
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Prote AG.
Removing
– Pull out oil dipstick.
– Remove vibration damper ⇒ page 60 .
– Turn crankshaft by bolt for toothed belt sprocket 2 turns in en‐

AG. Volkswagen AG d
agen oes
ksw not
by Vol
Caddy 2011
gu
ara
➤
d
4-cylinder diesel engineor(2.0
ise l engine, common rail) - Edition 09.2016 nte
eo
th
s au ra
c
Version A: lock crankshaft pulley with mark in position
s
ce
e
nl
pt
du
an
itte
y li
T10050- .
erm
ab
ility
ot p
• Marks on toothed belt pulley -2- and crankshaft stop - T10050-
wit
, is n
-1- must align.
h re
hole
• Pin of crankshaft stop - T10050- must engage in drilling in
spec
es, in part or in w
sealing flange.
t to the co
• The crankshaft stop - T10050- can be pushed onto the toothed
belt pulley only from the face side.
rrectness of i
l purpos
For crankshaft pulleys with a mark, it is also possible to use
nform
ercia
m
at
om
T10490- .
ion
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ate
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or

f
en
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t.
in sealing flange.
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Cop py
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Prote AG.
Version B: lock crankshaft pulley without mark in position
Note
Use only the crankshaft stop - T10490- to lock crankshaft pulleys

without a mark in position.

T10490- .
in sealing flange.
Continued for all

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
Balancer shaft module with 8 threaded connection points olksw not
byV gu
ara
ed
– Unscrew bolts in sequence -8 to 1-, and remove balance
horis shaft nte
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module together with oil pump. aut ra
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ss
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un
pt
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ab
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t to the co
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f inform
mer
atio
m
Balancer shaft module with 6 threaded connection points

o
n
c
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or
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– Unscrew bolts in sequence -6 to 1-, and remove balance shaft
te
sd
va
module together with oil pump.

i
o
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cum
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t.
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Note C py
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♦ Installing a new balancer shaft module ⇒ page 192 . by c lksw
cted agen
Prote AG.
♦ Reinstallation of balancer shaft module ⇒ page 196 .
4.3 Installing a new balancer shaft module

Caddy 2011 ➤

equipment required
♦ Bits XZN 12 - T10099-
♦ Locking device - T10255-
♦ 14 mm tool insert - T10393-
lkswage es n
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itte
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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
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
AG. Vocommon
lkswagen A rail) - Edition 09.2016 n G do
wage es n
Volks ot g
Procedure ed
by ua
ran
oris tee
th or
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ss
Note
ce
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un
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itte
♦ The spur gear drive of the balancer shaft module must be in‐
y li
rm
ab
stalled with correct tooth backlash.
pe
ility
ot
♦ A coating is applied to the new intermediate gear wheel to set
wit
, is n
h re
the correct tooth backlash.
hole
spec
♦ Intermediate gear wheels that have a white point are partly
es, in part or in w
t to the co
coated around the circumference. Intermediate gear wheels
without a white spot are fully coated around the circumference
♦ The coating wears off after a short time. This thereby sets the
rrectness of i
tooth backlash.
l purpos
♦ For this reason a new balancer shaft module must always be

installed with a new intermediate gear wheel with special coat‐
ing.
nform
ercia
♦ A white spot is positioned only on partly coated intermediate

m
a
com
ti
gear wheel to ensure correct installation position.
on in
r
te o
thi
♦ For intermediate gear wheels with coating around the com‐
s
iva
plete circumference the installation position is not relevant.
do
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rp
cum
fo
♦ Bolts that are firmly tightened at a specified angle must be
en
ng
t.
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renewed.
Co
Cop py
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• The crankshaft is locked with crankshaft stop - T10050- or
co Vo
by lksw
cted
agen
Prote AG.
Caution
The threaded connection of the intermediate gear wheel must

be loosened to position the balancer shaft module. When doing
this, do not loosen the bolt fully to prevent that the thrust wash‐
er does not slip behind the intermediate gear wheel. Thrust
washer installation position ⇒ page 189
Note
For illustration purposes the following procedure is described with

sealing flange removed.
– Before positioning balancer shaft module on cylinder block,

loosen bolt -1- for intermediate gear wheel approx. 45°.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balance shaft module on cylinder block.
– Place balancer shaft module on cylinder block and then tight‐
en.
Note
Take care not to damage coating on intermediate gear wheel.

Caddy 2011 ➤
– Lock balancer shaft with locking device - T10255- . To do this,

turn balancer shaft if necessary.
• Locking tool pin must engage in groove in balancer shaft when
doing this.
– Carefully fit gear wheel of balancer shaft onto balancer shaft.

While doing this, press intermediate gear a little to one side.
Note
♦ Coating on intermediate gear wheel must not be damaged.

AG. Volkswagen AG d
agen
♦ Ensure threaded holes in balancer shaft are centralVwithin
olks
w oes
not
elongated holes of balancer shaft gear wheel. ed
by gu
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♦ If elongated holes in balancer shaft gear wheel
ut
h
cannot be ra
sa
aligned with the threaded holes, the balancer shaft gear wheel
s c
ce
le
must be turned further by a corresponding number of teeth and

un
pt
must be mounted again.
an
d
itte
y li
erm
ab
ility
– Securely tighten balancer shaft gear wheel -arrows-.
ot p
wit
is n
– Remove locking tool - T10255- .
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
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t.
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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
The following 3 procedures must be performed simultaneously

(2nd mechanic required):
– Press intermediate gear -3- forcefully (with assistance of a
wooden rod if necessary) in -direction of arrow- into teeth of
drive gear wheel -2- and balancer shaft gear wheel -1- so that
they mesh.
– When doing so, turn the balancer shaft gear wheel -1- slightly
in an anticlockwise direction.
– Firmly tighten bolt for intermediate gear wheel using bit -
T10099- and 14 mm tool insert - T10393-
⇒ Item 14 (page 188) .
– Remove crankshaft stop .
Note
No backlash may be perceptible after installing intermediate gear

wheel. This can be checked by hand using light force.
Continue installation in reverse order of removal. When doing this,

observe the following:
– Install vibration damper ⇒ page 60 .
Torque settings
page 187
4.4 Installing a previously used balancer

shaft module again olks
wage
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Caution tho eo
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ss
ce
If the bolt for the intermediate wheel has been loosened, a new
e
nl
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intermediate wheel with coating must be installed, and the hub

an
itte
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⇒ Item 15 (page 188) including bolt ⇒ Item 14 (page 188) and

erm
ab
thrust washers must be renewed. This also applies to replace‐

ility
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ment of the drive gear wheel on the crankshaft and to removal

wit
, is n
of the crankshaft. Otherwise, the tooth backlash will be incor‐

h re
hole
rect. Procedure when installing ⇒ page 192 .

spec
es, in part or in w
t to the co
Note
rrectness of i
l purpos
♦ If the previously used balancer shaft module is to be reinstalled

and the drive gear wheel on crankshaft was renewed or the
crankshaft was removed, proceed as follows. The intermedi‐
nform
ercia
ate gear wheel must also not have been loosened.

m
at
♦ Bolts that are firmly tightened at a specified angle must be

om
ion
renewed.
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
196
cted agen
Prote AG.
Rep. gr.17 - Lubrication
Caddy 2011 ➤
– Lock balancer shaft with locking device - T10255- . To do this,

turn balancer shaft if necessary.
• Locking tool pin must engage in groove in balancer shaft when
doing this.
– Check to see whether both dowel sleeves are in place to cor‐
rectly position balance shaft module on cylinder block.
– Place balancer shaft module on cylinder block.
• The intermediate gear wheel must mesh in the crankshaft
drive gear wheel when the balancer shaft is locked.
• The intermediate gear wheel must have a slight tooth back‐
lash.
– Remove crankshaft stop - T10050- or crankshaft stop -
T10490- .
Continue installation in reverse order of removal. When doing this,
observe the following:
– Install vibration damper ⇒ page 60 .
Torque settings
page 187 gen AG
. Volkswagen AG
a does
lksw n
♦ ⇒ “2.1 Assembly overview
db
y V- toothed belt drive”, page 123t gua
o o
e ran
ris tee
tho or
au ac
ss
ce
le
un
pt
an
d
itte
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erm
ab
ility
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wit
is n
h re
ole,
spec
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
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
Caddy 2011 ➤ d by ara
ise nte
r
4-cylinder diesel engine
ut (2.0 l engine, common rail) - Edition 09.2016
ho eo
ra
s a c
s
ce
e
nl
pt
5 Oil circuit
du
an
itte
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erm
ab
⇒ “5.1 Assembly overview - oil circuit”, page 198
ility
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wit
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⇒ “5.2 Removing and installing oil line for turbocharger”,
h re
page 198
hole
spec
es, in part or in w
5.1 Assembly overview - oil circuit
t to the co
1 - Bolt
rrectness of i
❑ 20 Nm
l purpos
2 - Oil supply line

nform
ercia
⇒ page 198
m
at
om
3 - Oil return line
ion
c
in t
r
❑ Renew seal after each

o
his
te
removal
a
do
priv
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or
4 - Nut
f
en
ng
t.
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❑ 22 Nm
Co
Cop py
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5 - Nut
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pyri by
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❑ Renew after removal Prote
cted AG.
agen
❑ 22 Nm
6 - Connection pipe to exhaust
gas recirculation cooler
❑ Renew seals after each
removal
7 - Bolt
❑ 10 Nm
8 - Support
9 - Banjo bolt
❑ 60 Nm
10 - Banjo bolt
❑ Renew seals after each
removal
❑ 30 Nm
11 - Bolt
❑ 9 Nm
5.2 Removing and installing oil line for tur‐

bocharger

Caddy 2011 ➤
♦ Torque wrench - V.A.G 1331- .
♦ Tool set - T10395-
lkswage es n
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d ran
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itte
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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
nform
mercia
at
om
ion
c
in t
r
Removing
o
his
ate
do
riv

p
cum
or
terior; Rep. gr. 66 ; Noise insulation .

f
en
ng
t.
yi Co
– Unscrew bolts -1- and remove axle shaft shield. t. Cop py
rig
gh ht
All-wheel drive vehicles yri
p by
co Vo
by lksw
cted
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel
agen
Prote AG.
box .
Loosen particulate filter.
to create space for removing and installing the oil supply line with
turbocharger support.
5. Oil circuit 199

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

G450- -2- and unscrew securing bolt -3-. n AG. Volkswagen AG do
lkswage es n
o ot g
– Remove bolt -4- and pull exhaust gas pressure sensor 1 - d byV ua
ran
G450- off bracket -arrow-. o
ir se tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
bocharger.
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.

Caddy 2011 ➤
– Unscrew nuts -2-.
Caution
Risk of damage to damper element.

♦ Do not bend damper elements in front exhaust pipe by
more than 10°.
– Place particulate filter -1- aside. agen

AG. Volkswagen AG d
oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
ot
wit
, is n
h re
hole
– Now you can access the securing bolt on the retaining clamp
spec
-arrow- for the oil return line on the turbocharger support. Un‐
es, in part or in w
t to the co
screw bolt -arrow-.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
– Remove connection pipe -2- leading to cooler for exhaust gas
r
rp
cum
recirculation.
fo
en
ng
t.
yi Co
Catch leaking oil with used oil collection and extraction unit - Cop py
t. rig
V.A.G 1782- . opyri
gh by
Vo
ht
by c lksw
cted agen
Prote AG.
5. Oil circuit 201

Caddy 2011 ➤
– Unscrew bolt -3- of turbocharger support on turbocharger.

– If fitted, detach coolant pipe for auxiliary heater and push aside
slightly.
– Unscrew banjo bolt -5- and union nut -2- of oil supply line and
remove oil supply line.
– Unscrew banjo bolt -4- of turbocharger support from crank‐
case.
– Unscrew bolts -1- on turbocharger and remove turbocharger
support.
Installing
Note
. Volkswagen AG
gen AG
♦ Renew gaskets, seals, O-rings and self-locking nuts ⇒ ETKA
a oes d
ksw not
Vol
(Electronic Parts Catalogue)ed by gu
ara
is nte
or
♦ If the particulate filter or
auththe exhaust gas pressure sensor 1 - eo
ra
G450- is renewed, then ss the sensor must, without exception, c
be adapted ⇒ Vehicle diagnostic tester.
ce
e
nl
pt
du
an
itte
♦ After working on the exhaust system, ensure that the system
y li
erm
ab
is not under stress and that there is sufficient clearance to the
ility
ot p
bodywork. If necessary, loosen double clamp and align si‐
wit
, is n
lencer and exhaust pipe so that sufficient clearance is main‐
h re
tained to the bodywork and the support rings are evenly
hole
spec
loaded.
es, in part or in w
• The work procedure must be followed to ensure that the com‐ t to the co
bined flange (oil supply and return line) together with the
turbocharger support are installed tension-free.
rrectness of i
• This ensures that the turbocharger support is installed tension-

l purpos
free between crankcase and turbocharger.

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.

AG. Volkswagen AG d
agen oes Caddy 2011 ➤
olksw not
4-cylinder diesel engine d by V(2.0 l engine, common rail) - Editiongu
ara 09.2016
ise nte
or eo
h
– Fit turbocharger support on turbocharger and
s aut screw in bolts ra
c
-1- just loosely. s
ce
le
un
pt
– Secure turbocharger support with banjo bolt -4- loosely on
an
d
itte
y li
crankcase.
rm
ab
pe
ility
– Screw union nut -2- of oil supply line loosely on turbocharger.
ot
wit
, is n
h re
– Then screw banjo bolt -4- of oil supply line loosely on crank‐
hole
case.
spec
es, in part or in w
t to the co
– Then tighten turbocharger support alternately with banjo bolt
-4- and bolts -1- in increments on crankcase and turbocharger
until torque setting is reached.
rrectness of i
– Then tighten union nut -2- of oil supply line on turbocharger.
l purpos
– Then tighten banjo bolt -5- of oil supply line on crankcase.

– Finally tighten the bolt on the oil supply line/turbocharger sup‐
nform
ercia
port clamp.
m
a
com
t
– Then tighten bolt -3- of turbocharger support on turbocharger.
ion in
r
te o
Install particulate filter ⇒ page 354 .
thi
s
iva
do
Installation position of exhaust gas temperature sender -G235- .
r
rp
cum
fo
en
g

n
t.
yi Co
Cop py
– Install right drive shaft ⇒ Running gear, axles, steering; Rep. ht. rig
rig ht
gr. 40 ; Drive shafts; Removing and installing drive shaft .
py by
co Vo
by lksw
cted agen
Prote AG.
Angled shaft must have a distance -a- = 3 … 5 mm to bolting of

turbocharger support.
Torque settings
♦ ⇒ “5.1 Assembly overview - oil circuit”, page 198
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐
tion”, page 363
5. Oil circuit 203

Caddy 2011 ➤
19 – Cooling
1 Cooling system/coolant
⇒ “1.1 Coolant hose schematic diagram”, page 204
⇒ “1.2 Coolant hose connection diagram, gearbox side”,
page 206
⇒ “1.3 Draining and adding coolant”, page 207
⇒ “1.4 Checking cooling system for leaks”, page 212
⇒ “1.5 Checking engine oil cooler for leaks”, page 214
1.1 Coolant hose schematic diagram
1 - Coolant expansion tank

❑ With cap
❑ Checking pressure re‐
lief valve in cap
⇒ page 213 .
2 - Cylinder head and cylinder
block
placing wage
es n
lks ot g
Vo
3 - Exhaust gas recirculation ed
by ua
ran
cooler horis tee
ut or
❑ Renew coolant afterssre‐
a ac
placing
ce
le
un
pt
❑ Check exhaust gas re‐

an
d
itte
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circulation cooler for

erm
ab
leaks ⇒ page 284 .

ility
ot p
wit
is n
4 - Auxiliary heater
h re
ole,
❑ With recirculation pump

spec
- V55- .
t to the co
❑ Not necessarily instal‐

led
rrectne
5 - Heat exchanger for heater

s
placing
s o
cial p
f i
6 - Gear oil cooler

nform
mer
❑ Only for dual clutch

atio
gearbox.
om
n
c

or
n thi
e
placing
t
sd
iva
o
pr
7 - Thermostat
um
r
fo
en
ng
t.
❑ Only for dual clutch
yi Co
op
gearbox.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
204 Rep. gr.19 - Cooling

Caddy 2011 ➤
8 - Coolant circulation pump 2 - V178-
Caution
After fitting a new coolant
circuit pump, it is essen‐
tial to bleed the cooling
system using the VAS
6096 ⇒ page 207 . If this
is not done, air inclusions
can cause consequential
damage to the exhaust
gas recirculation cooler
as a result of overheat‐
ing. agen
AG. Volkswagen AG d
oes
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byV gu
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ed
is nte
9 - Radiator for engine coolant hor eo
aut ra
❑ Renew coolant after replacing ss c
ce
le
un
pt
10 - Thermostat
an
d
itte
y li
❑ Not necessarily installed
rm
ab
pe
ility
11 - Engine oil cooler
ot
wit
, is n
h re
12 - 4/2-way valve with thermostat
hole
spec
es, in part or in w
t to the co
13 - Coolant pump
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.
1. Cooling system/coolant 205

Caddy 2011 ➤
1.2 Coolant hose connection diagram, gearbox side
1 - Coolant hose, radiator sup‐

ply
2 - Coolant hose to breather
pipe
3 - Coolant hose, return line to
exhaust gas recirculation cool‐
er
4 - Coolant hose, radiator re‐
turn
5 - Coolant hose, supply to
heat exchanger for heater
6 - Coolant hose, return to heat
exchanger for heater
7 - Coolant hose, supply line to
exhaust gas recirculation cool‐
er
8 - Coolant hose, gear oil cool‐
er supply
9 - Gear oil cooler
10 - Coolant hose, »gear oil
cooler return«
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
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.

Caddy 2011 ➤
1.3 Draining and adding coolant

equipment required
♦ Refractometer - T10007 A-
- VAS 6208-
♦ Hose clamp pliers - VAS
6340-
♦ Coolant system charge unit
- VAS 6096-
♦ Adapter for cooling system
tester - V.A.G 1274/8-
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
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
Draining
nf
ercia
or
WARNING
m
m
atio
om
n in
c
Risk of scalding from hot steam or hot coolant.

or
thi
te
sd
a
On a warm engine, the cooling system is under high pressure.

iv
o
r
rp
cu
o
Cover filler cap on coolant expansion tank with a cloth, and

f
en
ng
t.
open it carefully to release pressure.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤ agen
AG. Volkswagen AG d
oes
ksw
4-cylinder diesel engine (2.0 l engine, commonbyrail)
Vol - Edition 09.2016 not
gu
ara
ed nte
oris
– Open filler cap on coolant expansion tank. au
th e or
ac
ss
ce
e
nl
pt
du
an
itte
y li
– Place drip tray for workshop hoist - VAS 6208- beneath en‐
erm
ab
ility
gine.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Loosen hose clamps -1- and -2- and remove air hose.
l purpos
nf
ercia
Note
orm
m
atio
m
To prevent ingress of coolant, seal connection on charge air cool‐

o
n in
c
er using a clean plug from engine bung set - VAS 6122- .

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
o
by c lksw
cted agen
Prote AG.
– Pull coolant hoses -1- off coolant circulation pump 2 - V178-
-2-.
– Disconnect lower coolant hose from radiator, lift retaining clip

-arrow- when doing this, and drain off coolant.

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

off engine oil cooler -arrow-.
Note
Please observe disposal instructions!
Filling
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
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.

Caddy 2011 ➤
Note
♦ Only distilled water may be used for mixing coolant additives.

The use of distilled water ensures optimum protection against
corrosion.
♦ The water used for mixing has a major influence on the effec‐
tiveness of the coolant. Since water quality differs from country
to country and even region to region, it is necessary to set a
standard for the quality of water to be used. Distilled water
fulfils all requirements. Therefore, distilled water must be used
when mixing coolant for topping up or renewing coolant.
♦ Use only coolant additives which conform with the ⇒ Elec‐
tronic Parts Catalogue (ETKA) . Other coolant additives may
reduce corrosion protection substantially. The resulting dam‐
age could lead to loss of coolant and subsequent severe
damage to the engine.
♦ Mixed in the proper proportions, coolant inhibits frost and cor‐
rosion damage as well as scaling. Such additives also raise
the boiling point of the coolant. Therefore, the cooling system
must be filled all year round with a coolant additive.
♦ Because of its high boiling point, the coolant improves engine
reliability under heavy loads, particularly in countries with trop‐
ical climates. swa
gen AG
. Volkswagen AG
does
k not
Vol
♦ The refractometer - T10007A- must be used toeddetermine the
by gu
ara
current anti-freeze value. tho
ris nte
eo
au ra
♦ Frost protection must be guaranteed as a min‐ down
ss to -25°C c
ce
e
imum and, in countries with arctic conditions, down to approx.

nl
pt
du
-36°C. Increasing the frost protection is permissible only if cli‐
an
itte
y li
matic conditions require stronger frost protection. It may, how‐
erm
ab
ever, be increased only to a maximum of -48 °C. Otherwise,
ility
ot p
the cooling effect will be impaired.
wit
, is n
h re
♦ Do not reduce the coolant concentration by adding water even
hole
spec
in warmer seasons and in warmer countries. Frost protection
es, in part or in w
must be guaranteed down to at least -25°C.

♦ Read off anti-freeze figures for respective replenished coolant t to the co
additives.
rrectness of i
♦ The temperature read off the refractometer - T10007A- corre‐

l purpos
sponds the »ice flocculation point«. Flakes of ice may start

forming in the coolant below this temperature.
nform
ercia
♦ Never reuse old coolant.

m
at
♦ Use only a water/coolant additive mixture as a slip agent for

om
io
coolant hoses.
n
c
in t
or
his
ate
do
riv
Recommended mixture ratios:

p
cum
for
en
g
Frost Coolant additive Coolant ad‐ Distilled wa‐

n
t.
yi Co
op
protection to portion ditive 1) ter1) C py
t. rig
gh ht
yri
-25°C 40% 3.2 l 4.8 l
p by
co Vo
-36°C 50% 4.0 l 4.0 l
by lksw
cted agen
Prote AG.
1) The quantity of coolant can vary depending upon vehicle equipment.
– Reconnect coolant hoses, and secure them with clamps.

– Reconnect connecting piece, and secure it with retaining clips.

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-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
Note ise
d b ara
nte
or eo
th
u ra
Exhaust air takes a slight
ss a
quantity of coolant along with it; this c
should be collected.
ce
e
nl
pt
du
an
itte
y li
– Close valves -A- and -B- (turn lever transverse to direction of
erm
ab
flow to do this).
ility
ot p
wit
, is n
– Connect hose -4- to compressed air.
h re
hole
spec
• Pressure: 6 to 10 bar.
es, in part or in w
t to the co
– Open valve -B-; turn lever in direction of flow to do this.
• In cooling system, vacuum is generated by suction jet pump;
rrectness of i
needle of gauge must move into green area.
l purpos
– 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.
nf
ercia
orm
– Close valve -A- again.
m
atio
om
n in
c
– Leave valve -B- open for a further 2 minutes.

or
thi
te
sd
• Vacuum continues to be generated in the cooling system by

iva
o
r
the suction jet pump; the needle of gauge must remain in green
rp
cu
o
range.
f
en
ng
t.
yi Co
op
– Close valve -B-.
C py
t. rig
gh ht
yri by
• The needle on the gauge should stop in the green zone. The cop Vo
by lksw
vacuum level in the cooling system is then sufficient for sub‐
cted agen
Prote AG.
sequent filling.
Note
♦ If the needle does not reach the green zone, repeat the proc‐
ess.
♦ If vacuum drops, cooling system must be checked for leaks.
– Pull off compressed air hose.

– Open valve -A-.
• The vacuum in the cooling system causes coolant to be ex‐
tracted from coolant expansion tank of cooling system charge
unit - VAS 6096- and the cooling system to be filled.
– Then, remove cooling system charge unit - VAS 6096- from
coolant expansion tank again.
– Fill coolant up to max. mark.

Caddy 2011 ➤
Without cooling system charge unit - VAS 6096- :

– Slowly fill coolant in up to upper marking of hatched field on
expansion tank.
– Fit expansion tank cap.
– Start engine, and maintain engine speed at approx. 2000 rpm
for approx. 3 minutes.
olkswagen AG
en AG. V
– Then run engine at idling speed until radiator fan cuts in.olkswag does
not
V gu
by ara
– Check coolant level and top up as needed. When engine
ris
ed is at nte
normal operating temperature, the coolant levelaumust
tho
be at the eo
ra
upper mark; when engine is cold, in the middle
ss of the shaded c
field.
ce
le
un
pt
an
d
itte
y li
1.4 Checking cooling system for leaks
erm
ab
ility
ot p
wit
is n
h re
ole,
♦ Cooling system tester - V.A.G 1274 B-
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
c
♦ Adapter for cooling system tester - V.A.G 1274/8-
um
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ Adapter for cooling system tester - V.A.G 1274/9-
Procedure
• Engine at operating temperature.

Caddy 2011 ➤
WARNING agen
AG. Volkswagen AG d
oes
olksw not
byV gu
Risk of scalding from hot steam rise dor hot coolant. ara
nte
tho eo
On a warm engine, the cooling
s au system is under high pressure. ra
c
s
ce
le
Cover filler cap on coolant expansion tank with a cloth, and
un
pt
open it carefully to release pressure.
an
d
itte
y li
rm
ab
pe
ility
ot
– Open filler cap on expansion tank.
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
– Fit cooling system tester - V.A.G 1274 B- with adapter -

te o
thi
V.A.G 1274/8- to coolant expansion tank.
s
iva
do
r
rp
cum
– Install connecting piece - V.A.G 1274 B/1- in adapter for cool‐
fo
en
g
ing system tester - V.A.G 1274/8- .

n
t.
yi Co
Cop py
– Join connection piece - V.A.G 1274 B/1- to cooling system ht. rig
rig ht
tester - V.A.G 1274 B- using connecting hose supplied.
py by
co Vo
by lksw
cted agen
– Build up pressure of approx. 1.0 bar using hand pump of cool‐
Prote AG.
ing system tester.
DANGER!
Risk of scalding! Before the cooling system tester - V.A.G 1274

B- is disconnected from the connecting hose or the connector
- V.A.G 1274 B/1- , reduction of the pressure is essential. To
do this, press pressure relief valve on cooling system tester -
V.A.G 1274 B- until pressure gauge displays value of »0«.
If the pressure drops:

– Search for leaks within engine compartment and on underside
of vehicle.
Check pressure relief valve in cap.

– Fit cooling system tester - V.A.G 1274 B- with adapter -
V.A.G 1274/9- to filler cap -1-.
– Build up pressure using hand pump of cooling system tester.
• The pressure relief valve must open at a pressure of 1.4 to
1.6 bar.
– Renew filler cap, if pressure relief valve does not open as de‐
scribed.

Caddy 2011 ➤
1.5 Checking engine oil cooler for leaks

equipment required
♦ Hose clamps, up 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-
♦ Drip tray - V.A.G 1306- or
drip tray - VAS 6208-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
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.

Caddy 2011 ➤

Not illustrated
♦ Expansion tank
♦ Sealing cap
♦ Commercially available plug
AG. Volkswagen AG d
agen
♦ Commercially available hose Volksw
oes
not
gu
by ara
d
Condition: orise nte
eo
th
u ra
• Engine cold ss a c
ce
le
un
Test sequence
pt
an
d
itte
y li
– If fitted, remove noise insulation ⇒ General body repairs, ex‐ erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Loosen hose clip on engine oil cooler with spring-type clip pli‐
ers - VAS 5024 A- .
t to the co
– Remove engine oil cooler with housing ⇒ page 175 .
rrectne
Note
ss o
♦ Collect escaping coolant with drip tray for workshop hoists -
cial p
f in
VAS 6208- .
form
mer
♦ Collect leaking engine oil with an absorbent cleaning cloth, if
atio
m
necessary.
o
n
c
i
or
n thi
te
sd
iva
o
r
Checking when removed

p
cum
r
fo
en
ng
– Clamp the casing with the old gasket onto a suitable, flat clean
t.
yi Co
op
surface with the help of a bar clamp -4-.
C py
t. rig
gh ht
yri by
– Attach plug -2- to venting connection of expansion tank -1-. cop Vo
by lksw
cted agen
Prote
– Attach coolant hose -3- to engine oil cooler -5- and to expan‐
AG.
sion tank -1-.

– Fill expansion tank up to max. mark.
– Fit cooling system tester - V.A.G 1274- with adapter for cooling
system tester - V.A.G 1274/8- on coolant expansion tank -1-.
– Generate about 1.6 bar pressure using hand pump of tester.
– Observe pressure drop on pressure gauge. A pressure drop
within 10 minutes is not permitted.
If the pressure drops:
– Renew engine oil cooler ⇒ page 175 .
Install in reverse order of removal. When doing this, observe the
following:
– Renew housing seal.
– Check coolant level and, if necessary, replenish ⇒ page 207 .
– Check engine oil level and, if necessary, replenish
⇒ page 172 .

Caddy 2011 ➤
2 Coolant pump, regulation of cooling

systemlkswagen AG. Volkswagen AG does n
o ot g
yV u
⇒ “2.1 Assemblyiseoverview
db - coolant pump, thermostat”,aran
page 216 uthor tee
o ra
sa c
⇒ “2.2 Removing
s and installing coolant pump”, page 217
ce
e
nl
pt
du
⇒ “2.3 Removing and installing 4/2-way valve with thermostat”,
an
itte
y li
page 218
erm
ab
ility
ot p
⇒ “2.4 Removing and installing coolant temperature sender G62
wit
, is n
”, page 220
h re
hole
⇒ “2.5 Removing and installing radiator outlet coolant tempera‐
spec
es, in part or in w
ture sender G83 ”, page 222
t to the co
2.1 Assembly overview - coolant pump, thermostat
rrectness of i
1 - Coolant pump
l purpos

⇒ page 217
nf
ercia
or
2 - Bolt
m
m
atio
m
❑ 15 Nm
o
n in
or c
3 - O-ring
thi
te
sd
iva

o
r
rp
cu
o
m
f
en
ng
4 - O-ring yi
t.
Co
op
C py
t. rig
gh ht
yri by
5 - 4/2-way valve with thermo‐
op Vo
by c lksw
stat
cted agen
Prote AG.
❑ The thermostat is loca‐
ted within the 4/2-way
valve and cannot be ex‐
changed individually.
⇒ page 218
6 - Bolt
❑ 15 Nm

Caddy 2011 ➤
2.2 Removing and installing coolant pump

equipment required
- 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
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
Removing
t to the co

rrectness of i

l purpos

– Remove coolant pump bolts -1- and carefully remove coolant
nf
ercia
pump -2-.
orm
m
Installing
atio
om
n in
c

or
thi
te
sd
iva
o
r
rp
cu
Note
o
m
f
en
ng
t.
yi Co
op py
♦ Renew gaskets and seals. t. C rig
gh ht
pyri by
♦ The coolant pump plug faces downwards.
o Vo
by c lksw
cted agen
Prote AG.
2. Coolant pump, regulation of cooling system 217

Caddy 2011 ➤
AG. Volkswagen AG d
– Moisten new O-ring -3- with coolant. agen oes
olksw not
V gu
by ara
– Insert coolant pump -2- into cylinder block and tighten bolts rised
nte
-1-. aut
ho eo
ra
ss c
– Install toothed belt ⇒ page 125 .
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
Torque settings
h re
hole
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
spec
es, in part or in w
page 216
t to the co
rrectness of i
l purpos
2.3 Removing and installing 4/2-way valve with thermostat
nform
ercia

m
a
equipment required
com
tion in
r
♦ 10 mm jointed spanner -
te o
thi
3185-
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
♦ Torx bit T40 - T10058- t. Cop py
rig
gh ht
♦ Torque wrench - V.A.G yri
p by
o Vo
1331/-
by c lksw
cted agen
Prote AG.
- VAS 6208-
♦ Hose clamp pliers - VAS
6340-

Caddy 2011 ➤
♦ Flex-head socket wrench XZN 8 - T10445-
Note
The thermostat is located within the 4/2-way valve and cannot be

renew individually.
Removing
– Open clamp -2-.
– Disconnect electrical connection -1- on charge pressure send‐
er - G31- / intake air temperature sensor - G42- and remove
right charge air pipe.
– Remove throttle valve module - J338- ⇒ page 325 .
– Remove alternator ⇒ Electrical system; Rep. gr. 27 ; Alter‐
nator; Removing and installing alternator .
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
rm
ab
pe
ility
– Remove coolant hoses from unions -A-, -B- and -C-.

ot
wit
, is n
h re
– Loosen securing bolt of coolant pipe behind oil filter a few turns
hole
using universal joint socket XZN 8 - T10445- .

spec
es, in part or in w
t to the co
– Pull coolant pipe out of connection -C-.

– Unscrew securing bolts -3- for 4/2-way valve -2-.
rrectness of i
– Pull 4/2-way valve out of cylinder block and then pull to left to
separate connection -C- from coolant pipe.
l purpos
Installing
nform
ercia

m
– Clean and smoothen sealing surface for O-ring.

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
219
co Vo
by lksw
cted
2. Coolant pump, regulation of cooling system
agen
Prote AG.
Caddy 2011 ➤
– Renew oil seal -1-.

– Wet the seal -1- with coolant.
– First fit 4/2-way valve -2- with connection -C- on coolant pipe
and then insert in crankcase as far as it will go.
– Tighten bolts -3-. AG. Volkswagen AG d
agen oes
olksw not
– Connect coolant hosesd by V as follows: gu
ara
ise nte
r
♦ -A-: Bypass uline
th to cylinder head
o eo
ra
s a c
s
♦ -B-: Expansion tank
ce
e
nl
pt
du
an
♦ -D-: Radiator return line
itte
y li
erm
ab
– Tighten the screw of the coolant pipe behind the oil filter with
ility
ot p
flex-head socket wrench XZN 8 - T10445- .
wit
, is n
h re
– Install charge air pipe.
hole
spec
– Install alternator ⇒ Electrical system; Rep. gr. 27 ; Removing
es, in part or in w
t to the co
and installing alternator .
– Install throttle valve module - J338- ⇒ page 325 .
rrectness of i
l purpos
Torque settings
♦ ⇒ “2.1 Assembly overview - coolant pump, thermostat”,
nform
ercia
page 216
m
at
♦ Alternator; Assembly overview - alternator ⇒ Alternator; Rep.

om
ion
gr. 27 ; Assembly overview - alternator

c
in t
or
his
ate
do
riv
2.4 Removing and installing coolant temper‐

p
cum
for
en
ature sender - G62-

ng
t.
yi Co
Cop py
. rig
ht ht
rig by
copy Vo
lksw
by
cted agen
Prote AG.
Removing
• Engine cold.

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

reduce pressure in cooling system.

lever - 80 - 200- . en AG. V
olkswagen AG
ag does
ksw not
– Loosen hose clip -3- and remove
by left air pipe.
Vol gu
ara
ed nte
ris
tho eo
au ra
Note ss c
ce
e
nl
pt
du
an
Disregard -items 1, 2, 4, 5-.
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
– Pull connector -4- off coolant temperature sender - G62- .
es, in part or in w
t to the co
Note
rrectness of i
Place a cloth under connecting piece to absorb escaping coolant.
l purpos
– Pull off retaining clip -3- and pull coolant temperature sender
- G62- out of screw connection.
nf
ercia
orm
m
atio
om
Note
n in
or c
thi
te
sd
a
-Items 1, 2- can be disregarded.

iv
o
r
rp
cu
o
m
f
en
ng
Installing
t.
yi Co
Cop py
. rig
t
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
♦ Renew O-ring.
♦ Insert new coolant temperature sender - G62- immediately in‐
to union to avoid loss of coolant.
– Check coolant level and top up if necessary ⇒ page 207 .

Torque settings

Caddy 2011 ➤
2.5 Removing and installing radiator outlet

coolant temperature sender - G83-
Removing
• Engine cold.
– Briefly open filler cap for coolant expansion tank in order to
reduce pressure in cooling system.

– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
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Caddy 2011 ➤
ra
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– Pull connector -2- off radiator outlet coolant temperature send‐
itte
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Note
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spec
Place a cloth underneath to absorb escaping coolant.
t to the co
– Pull off retaining clip -1- and pull coolant temperature sender
rrectne
at radiator outlet - G83- out of screw connection of coolant
pipe.
ss
Installing
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form
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♦ Renew O-ring.
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ng
t.
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to coolant pipe at radiator outlet to avoid loss of coolant. ht. Cop py
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– Check coolant level and top up if necessary ⇒ page 207 .
co lksw
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Caddy 2011 ➤
3 Radiator, radiator fan

⇒ “3.1 Assembly overview - radiator/radiator fan”, page 224
⇒ “3.2 Removing and installing radiator”, page 225
⇒ “3.3 Removing and installing radiator cowl with radiator fan”,
page 226
3.1 Assembly overview - radiator/radiator fan
1 - Radiator/cooler
❑ After renewing, renew
entire coolant.
⇒ page 225
2 - O-ring
❑ Renew if damaged
3 - Upper coolant hose
coolant hoses
⇒ page 204
4 - Cap
❑ Check using cooling
system tester -
V.A.G 1274- and adapt‐
er - V.A.G 1274/9-
⇒ page 212 .
5 - Connector
6 - Bolt
❑ 5 Nm agen
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❑ With coolant tempera‐
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❑ Checking cooling sys‐

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tem for leaks with cool‐

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ab
ing system tester -

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V.A.G 1274- and adapt‐

wit
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er - V.A.G 1274/8-
h re
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⇒ page 212
spec
8 - Lower coolant hose

t to the co

coolant hoses
⇒ page 204
rrectne
9 - Nut
ss
❑ 5 Nm
o
cial p
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10 - Bolt
form
mer
❑ 5 Nm
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Prote AG.

Caddy 2011 ➤
11 - Radiator fan - V7-

12 - Right radiator fan - V35-
13 - Connector
14 - Radiator cowl
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.
AG. Volkswagen AG d
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3.2 Removing and installing radiator
s ce
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equipment required
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♦ Torque wrench - V.A.G

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1783-
- VAS 6208-
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3. Radiator, radiator fan 225

Caddy 2011 ➤
Removing
– Remove air filter housing with connecting pipe ⇒ page 341 .
– Remove radiator cowl with radiator fan - V7- and remove right
radiator fan - V35- ⇒ page 226 .
– Pull coolant hoses off radiator.
– Remove radiator securing bolts ⇒ Item 10 (page 224) and re‐
move radiator.
Installing
Torque settings
3.3 Removing and installing radiator cowl

with radiator fan
Removing
– Remove air filter housing with connecting pipe ⇒ page 341 .
– Remove upper bolts -arrows- of air cowling.
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– Pull back securing lever -1- onto stop

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– Push down securing lever -2- and pull off connector

rrectness of i
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Prote AG.

Caddy 2011 ➤
– Unscrew lower bolts -arrows-.

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

– Unscrew nuts -arrows- and remove radiator fan.
Installing
Torque settings
AG. Volkswagen AG d
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3. Radiator, radiator fan 227

Caddy 2011 ➤
4 Coolant pipes
⇒ “4.1 Assembly overview - coolant pipes”, page 228
⇒ “4.2 Removing and installing front coolant pipe”, page 229
⇒ “4.3 Removing and installing upper front coolant pipe”,
page 233
n AG. Volkswagen A
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left
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4.1 Assembly overview - coolant pipes
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1 - Grommet
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❑ Not sold separately.
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2 - Sleeve
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❑ Not sold separately.
spec
t to the co
3 - Bolt
❑ 3 Nm
rrectne
4 - Bolt
❑ 40 Nm
ss
5 - Bracket
o
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❑ For coolant circulation form
mer
pump 2 - V178-
atio
m
6 - Front coolant pipe

o
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⇒ page 229
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9 - Right coolant pipe

10 - O-ring
11 - Retaining clip
12 - Radiator outlet coolant
temperature sender - G83-
⇒ page 222
13 - Bolt
❑ 8 Nm
14 - Nut
❑ 8 Nm
15 - Bolt
❑ 8 Nm
16 - Coolant line
17 - Seal

Caddy 2011 ➤
18 - Union
❑ For coolant hoses
19 - O-ring
20 - Radiator outlet coolant - G62-
21 - Centre hex stud
❑ 8 Nm
22 - Bolt
❑ 8 Nm
23 - Retaining clip
24 - Left coolant pipe
25 - Bolt
❑ 8 Nm
26 - Bolt
❑ 8 Nm
27 - Bolt
❑ 8 Nm
28 - Bolt
❑ 13 Nm
29 - Upper front coolant pipe
30 - Coolant circulation pump 2 - V178-
AG. Volkswagen AG d
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Special tools and workshop equipment required s
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4. Coolant pipes 229

Caddy 2011 ➤
♦ Hose clamps, up to 25 mm - 3094- for vehicles with dual clutch

gearbox
AG. Volkswagen AG d
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Removing
ce
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– Disconnect earth wire -arrow- from battery with ignition switch‐
h re
ed off ⇒ Electrical system; Rep. gr. 27 ; Disconnecting and
hole
spec
reconnecting battery .
es, in part or in w
t to the co
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
rrectness of i
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Prote AG.

Caddy 2011 ➤
– Remove battery tray. To do this, unscrew bolts -arrows-.
case.
– Unclip wiring harness from bracket -arrow-.

wage
Vehicles with dual clutch gearbox: yV
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– Clamp off coolant hoses using hose clamps to 25 mm - 3094-

and remove from gear oil cooler. To do this, loosen hose clips
-arrows-.
rrectness of i

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c
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231
Prote AG.
4. Coolant pipes
Caddy 2011 ➤
– Free wiring harness -arrows- and electrical connector -1- at

bracket.
AG. Volkswagen AG d
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– Remove air hose. To do this, loosen hose clips -1- and -2-.
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lever - 80 - 200- .
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– Loosen hose clips -1- and pull coolant hoses off. Prote AG.
Note
-Items 2, 3, 4- can be disregarded.

Caddy 2011 ➤
– Remove electrical connector -1- for Hall sender - G40- from

bracket.
– Remove bracket from front coolant pipe.
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– Loosen hose clips -2-
s aut -3- and pull coolant hoses off. ra
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s
– Unscrew bolts -arrows- and pull front coolant pipe out of 4/2-
ce
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un
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way valve.
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Installing
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Note
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– Moisten O-ring with coolant and slide onto front coolant pipe.
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– Push front coolant pipe into 4/2-way valve.

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Torque settings t. C rig
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♦ ⇒ “4.1 Assembly overview - coolant pipes”, page 228
o Vo
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Prote AG.
4.3 Removing and installing upper front

coolant pipe

Caddy 2011 ➤
Removing
– Loosen hose clips -1- -3-, and pull off coolant pipe.
– Remove top coolant pipe at front.
Installing
olkswagen AG
Install in reverse order of removal, observing the
swa
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en AG. V does
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– Add coolant ⇒ page 207 . ed
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Torque settings th
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♦ ⇒ “8.1 Assembly overview - air filter housing”, page 340 y li

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4.4 Removing and installing left coolant pipe

wit
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spec
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Prote AG.

Caddy 2011 ➤
AG. Volkswagen AG d
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wit
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spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
Removing
n
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t.
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t. C rig
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Prote AG.

Caddy 2011 ➤
– Remove air hose. To do this, loosen hose clips -1- and -2-.
AG. Volkswagen AG d
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spec
t to the co
lever - 80 - 200- .
rrectne
s
s o
gine.
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f inform
– Clamp off coolant hoses with hose clamps to 25 mm - 3094-
mer
and loosen hose clips -1- and -4-.

atio
om
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c
– Pull coolant hoses off left coolant pipe.

i
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– Remove rear left coolant pipe.

iv
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Installing
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t.
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C py
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Note Prote AG.

Torque settings
4.5 Removing and installing right coolant

pipe

Caddy 2011 ➤
AG. Volkswagen AG d
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mer
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t.
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Prote AG.
Removing
– Loosen bolt -1-. Undo bolt -2- and nut -3-.
– Remove bracket -4- from fuel filter, and lay fuel filter -7- aside
with fuel hoses -5- and -6- connected.
– Remove front right wheel housing liner ⇒ Rep. gr. 66 .
gine.

Caddy 2011 ➤ n AG. Volkswagen AG do
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– Pull connector -3- off radiator outlet
th coolant temperature send‐
o
or
au
er - G83- . ss
ac
ce
e
nl
– Clamp off coolant hoses using hose clamps up to 25 mm -
pt
du
an
3094- .
itte
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ility
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spec
es, in part or in w
t to the co
rrectness of i
– Loosen hose clip -arrows- and pull coolant hoses off right
l purpos
coolant pipe.
nf
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– Unscrew nut -1- and bolt -2- and remove right coolant pipe.
orm
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Installing
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Secure all hose connections with the hose clips corresponding to t. C rig
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original equipment ⇒ ETKA (Electronic Parts Catalogue) . yri
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Prote AG.
Torque settings

Caddy 2011 ➤
21 – Turbocharging/supercharging
1 Charge air system
⇒ “1.1 Assembly overview - charge air system”, page 239
⇒ “1.2 Assembly overview - charge-air hose connections”,
page 240
⇒ “1.3 Hose connections with screw-type clips”, page 241
⇒ “1.4 Removing and installing charge air cooler”, page 241
⇒ “1.5 Removing and installing charge air pipe”, page 243
⇒ “1.6 Removing and installing charge air pressure sender G31 /
intake air temperature sender G42 ”, page 244
⇒ “1.7 Checking charge air system for leaks”, page 245
1.1 Assembly overview - charge air system
1 - Intercooler
⇒ page 241
2 - Seal
3 - Bolt
❑ 5 Nm
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4 - Bearings lksw
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6 - Screw-type clip with “barb”. aut ra
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❑ Observe notes
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⇒ page 241 .
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7 - Air hose at bottom ab

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8 - Bolt wit
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❑ 5 Nm
hole
spec
9 - Charge air pressure sender

es, in part or in w
t to the co
- G31- / intake air temperature

sender - G42-
rrectness of i
⇒ page 244
l purpos
10 - O-ring
nform
ercia
11 - Air pipe (right side)

m
a
com
ti
12 - Screw-type clamp
on in
r
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❑ Observe notes
thi
s
iva
⇒ page 240 .
do
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rp
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fo
13 - Air hose at top

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t.
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14 - Bolt C py
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❑ 9 Nm yri
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15 - Grommet
agen
Prote AG.
1. Charge air system 239

Caddy 2011 ➤
16 - Air hose at top

17 - Left air pipe
18 - Sleeve
19 - Bolt
❑ 9 Nm
20 - Grommet
21 - Air hose at bottom
22 - Seal
1.2 Assembly overview - charge-air hose

connections
Note
wage es n
♦ Check all air hoses and pipes for firm seating and leaks beforey Volks ot g
carrying out tests or repairs. ed
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♦ Hose unions and air intake pipes and hoses must bes aufree of
t or
ac
oil and grease before installation. s
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♦ Secure all hose connections with the same type of hose clips
an
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as original equipment ⇒ Electronic Parts Catalogue .
erm
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ility
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♦ In order to be able to securely attach the air hoses on their
wit
is n
connections, the worm screws of the used hose clips have to
h re
be sprayed with penetrating spray before installing.
ole,
spec
t to the co
Caution
rrectne
The screw-type clips -A- on the charge air lines must always
be tightened as specified ⇒ page 240 . If the torque is too low
ss
or too high, the charge air hose may slip off the corrugated pipe
o
cial p
f
connection or the charge air pipe when the vehicle is used.
inform
mer
atio
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Installing air hoses with screw-type clips

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Specified torques for
rig
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1- Hose clip -a- = 13 mm wide: 5.5 Nm
lksw
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Prote AG.
2- Hose clip -b- = 9 mm wide: 3 Nm
240 Rep. gr.21 - Turbocharging/supercharging

Caddy 2011 ➤
1.3 Hose connections with screw-type clips
Caution
It is essential that the screw-type clips 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
Volkswa
• Do not loosen these hose clips and kpull
swa them back over
gen AG
. gen AG
does
the hose. Risk of damage to hose!
by Vol not
gu
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ise
• If a clamp has been removed, ho it must be renewed together
r tee
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with the hose. ss
a ac
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un
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ab
ility
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Screw-type clips with locking hooks -arrows- must only be loos‐
wit
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ened.
h re
ole,
spec
– Loosen bolt of screw-type clips -1- sufficiently to allow for re‐
moving hoses.
t to the co
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 rrectnes
or grease. Only use clean water.
s o
cial p
f inform
mer
atio
om
n
c
1.4 Removing and installing charge air cool‐

i
or
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e
er
t
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Removing
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op
– Open air intake cover. To do this, carefully release the catches
C py
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gh
-arrows-.
ht
pyri by
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cted agen
Prote AG.

Caddy 2011 ➤
– Press in locking lugs -1- and AG-3-

. Voand
lkswapull
gen Aconnecting hose -4-
off air filter housingo-2-. agen G do
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– Remove air ofilter
ris
ed ⇒ page 341 . nte
h eo
ut ra
– Bring lock
ss carrier into service position ⇒
a General body repairs,c
exterior; Rep. gr. 50 ; Bringing lock carrier into service position
ce
le
un
pt
and moving it back .
an
d
itte
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– Removing and installing air cowling together with radiator fan
erm
ab
ility
- V7- and right radiator fan - V35- ⇒ page 226 .
ot p
wit
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– Remove radiator together with connected coolant lines

h re
ole,
⇒ page 225 . spec

– Secure cooler with cable tie.

t to the co
– Unscrew bolts -arrows- from charge air cooler.

rrectne
Vehicles with air conditioning system:

ss o
WARNING
cial p
f inform
mer
Danger of injury due to coolant.

atio
om
♦ The air conditioner refrigerant circuit must not be opened.

n
c
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te
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Caution
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t.
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Danger of damage to condenser, refrigerant lines and hoses.gh ht
pyri by
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♦ Do not overstretch, kink or bend refrigerant lines and ho‐ Prote
cted AG.
agen
ses.
– Unscrew bolts -1- for charge air cooler and -2- for condenser.

Caddy 2011 ➤
– Unscrew bolt from lower right refrigerant line bracket on

charge air cooler.
– Secure condenser to lock carrier with cable ties.
Continued for all vehicles:n AG. Volkswagen A
ge G do
swa es
– Take out charge
by
Vol air cooler from underneath.ot gu
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Installing thori tee
or
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Install sin
s
reverse order of removal.
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pt
Torque settings
an
d
itte
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rm
ab
♦ ⇒ “1.1 Assembly overview - charge air system”, page 239
pe
ility
ot
wit
, is n
h re
hole
spec
1.5 Removing and installing charge air pipe
es, in part or in w
t to the co
Procedure
– Disconnect earth strap at battery with ignition switched off ⇒
rrectness of i
Electrical system; Rep. gr. 27 ; Disconnecting and connecting
battery.
l purpos
– Remove battery and battery tray ⇒ Electrical system; Rep. gr.

27 ; Removing and installing battery .
nform
ercia
m
a
com
t
pipe ⇒ page 341 .
ion in
r
te o
Observe instructions for hose connections with screw-type clips

thi
s
iva
⇒ page 241 .
do
r
rp
cum
fo
– Loosen clamps -1 - and -2- on connecting hose to pulsation

en
ng
t.
yi
damper. Unscrew securing bolt -3- from charge air pipe.
Co
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– Unscrew securing bolt -arrow- from charge air pipe
gh ht
pyri by
⇒ page 239 . Pull connecting hose from pulsation damper as
co Vo
by lksw
cted
far as possible.
agen
Prote AG.
– Unclip top coolant hose on charge air pipe -arrow-.

Caddy 2011 ➤
– Unclip wiring harnesses from charge air pipe -arrows-.

Observe instructions for hose connections with screw-type clips
⇒ page 241 .
– Remove connecting hose -arrow-.
– Remove bolts -arrows- of charge air pipe.

– Take out charge air pipe.
Installing agen
AG. Volkswagen AG d
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Install in reverse order of removal, observing d byV the following: gu
ara
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– First, fit all bolts of charge air pipe
ut
h in position and then tighten.
o eo
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s a c
s
– Renew any damaged cable ties and clips.
ce
le
un
pt
an
d
Torque settings
itte
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erm
ab

ility
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is n
h re
ole,
1.6 Removing and installing charge air pres‐

spec
sure sender - G31- / intake air tempera‐

t to the co
ture sender - G42-

rrectne
Removing
s

s o
cial p
f inform
mer
atio
om
n
c
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or
n thi
te
sd
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not Caddy 2011 ➤
byV gu
ara
4-cylinder dieselrisengine (2.0 l engine, common rail) - Edition
ed
nte 09.2016
ho eo
aut ra
– Pull connector -2- off charge air pressure
s sender - G31- / in‐
s c
ce
e
take air temperature sender - G42- .
nl
pt
du
an
itte
– Unscrew bolts -1- and pull charge pressure sender - G31- /
y li
erm
ab
intake air temperature sender - G42- out of air pipe.
ility
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wit
Installing
, is n
h re
hole
spec
es, in part or in w
– Renew O-ring.
t to the co
– Install noise insulation, if removed ⇒ General body repairs,
rrectness of i
Torque settings
l purpos
nform
ercia
1.7 Checking charge air system for leaks

m
at
om
io
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in t
or
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♦ Charge air system tester - V.A.G 1687-

at
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priv
cum
for
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rig ht
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co Vo
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Prote AG.
♦ Adapter - V.A.G 1687/10-


Caddy 2011 ➤
Removing
– Remove crankcase breather hose -arrow- from air pipe. To do
this, press release buttons.
– Seal union with a bung -2- (diameter 28 mm) from engine bung
set - VAS 6122- and secure with a clip -1-.
– Remove intake hose -1- from air filter.

– Insert adapter - V.A.G 1687/10- into intake hose -1- and se‐
cure with a clip.
Prepare charge air system tester - V.A.G 1687- as follows:
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
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– Unscrew pressure control valve -2- completely and close

ab
pe
ility
valves -3- and -4-.

ot
wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
To turn the pressure regulating valve -2- the knob must be pulled
upwards.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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cum
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t.
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Cop py
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gh ht
pyri by
Vo
co
246
by lksw
cted agen
Rep. gr.21 - Turbocharging/supercharging Prote AG.
Caddy 2011 ➤
ks to adapter - wage es n
– Connect charge air system tester - V.A.G y1687-
Vol ot g
ua
V.A.G 1687/10- as shown. ris
ed b ran
tee
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s au ac
s
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nl
pt
du
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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
rrectness of i
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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
Vo
co lksw
by
cted agen
Prote AG.

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-.
Caution
The pressure must not exceed 0.5 bar. If the pressure is too
high, this can cause damage to the charge air system.
– Adjust pressure to 0.5 bar with pressure control valve -2-.

– Open valve -4- and wait until test circuit is full. If necessary,
re-adjust pressure to 0.5 bar.
– Check charge air system for leaks as follows:
♦ by listening AG. Volkswagen AG d
agen oes
olksw not
♦ by feeling d by V gu
ara
rise nte
♦ with leak detector spray utho eo
ra
s a c
s
♦ or with the ultrasonic tester - V.A.G 1842- .
ce
le
un
pt
an
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erm
ab
Note
ility
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♦ Slight leaks on the intake side of turbocharger are permissible, h re

ole,
as the intake hoses are not designed for high-pressure. spec

♦ A small amount of air escapes through the valves and enters

t to the co
the engine. Therefore a holding pressure test is not possible.

♦ Ultrasonic tester - V.A.G 1842- ⇒ operating instructions
rrectne
♦ If a leak has been located, observe notes on charge air system

specified in assembly work ⇒ page 240 .
ss o
♦ Depressurise test circuit by detaching coupling from adapter -

cial p
f in
V.A.G 1687/10- before removing adapter.

form
mer
atio
om
n
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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 Exhaust turbocharger
⇒ “2.1 Assembly overview - turbocharger”, page 249
⇒ “2.2 Removing and installing turbocharger”, page 253
⇒ “2.3 Replacing vacuum unit with position sender for charge
pressure positioner G581 ”, page 258
⇒ “2.4 Removing and installing charge pressure control solenoid
valve N75 ”, page 264
2.1 Assembly overview - turbocharger

Note
♦ Sealed bolts and nuts must not be loosened.

♦ All hose connections are secured.
♦ Charge air system must be free of leaks.
♦ Renew self-locking nuts.
Volkswa
♦ Before installing the turbocharger,
swa
gen AG
.
fill the oil dsupply
gen AG
oes channel
(smaller diameter) by with a »splash« of engine oil “toguprevent
Volk not
a
dry start up”. rise d ara
nte
tho eo
♦ After installing
s au turbocharger, run engine for about 1 minute r aat
c
idling speed to ensure that oil is supplied to turbocharger.
s
ce
le
un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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cum
fo
en
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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.
2. Exhaust turbocharger 249

Caddy 2011 ➤
1 - Exhaust gas recirculation

pipe
❑ With flexible joint; do not
bend flexible joint - risk
of cracking
2 - Seal
3 - Bolt
❑ 17 Nm
wage es n
4 - Oil supply line yV
olks ot g
ua
d b
❑ Check for ocontinuity.
ris
e ran
tee
th or
❑ Befores installing, fill tur‐
au ac
bocharger with engine
s
ce
e
nl
oil at oil supply line con‐
pt
du
an
nection.
itte
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erm
ab
❑ 22 Nm
ility
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5 - Oil return line
, is n
h re
hole
6 - Seal
spec
es, in part or in w
t to the co
7 - Nut
❑ 24 Nm rrectness of i
8 - Heat shield
l purpos
9 - Exhaust turbocharger
❑ Must only be renewed
nform
ercia
together with exhaust

m
at
manifold and position

om
io
sender for charge pres‐

n
c
in t
or
sure positioner - G581- .

his
ate
do
riv
❑ Renewed together with

p
vacuum unit and regu‐

um
for
en
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lating flap potentiometer - G584- .

n
t.
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op
❑ Note tightening sequence and installation procedure ⇒ page 251 .
C py
ht. rig
rig ht
❑ Installation position of connecting hose at turbocharger ⇒ page 252
py by
co Vo
by lksw
cted
agen
Prote AG.
10 - Retaining ring
❑ Installation possible in one position only ⇒ page 252
11 - Seal
❑ Renew if damaged or leaking
12 - Pulsation damper
❑ Installation position of connecting hose at pulsation damper ⇒ page 252
13 - Bolt
❑ 9 Nm
14 - Intake connecting pipe
15 - Bolt
❑ Attached in inlet connection.
❑ 9 Nm
16 - O-ring

Caddy 2011 ➤
17 - Bracket
18 - Bolt
AG. Volkswagen AG d
❑ 15 Nm lksw
agen oes
not
Vo gu
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19 - Heat shield rise
d b ara
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20 - Seal s au ra
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e
nl
pt
du
an
21 - Nut
itte
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erm
ab
ility
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❑ 24 Nm
wit
, is n
h re
hole
22 - Exhaust gas temperature sender 1 - G235-
spec
es, in part or in w
t to the co
❑ Assembly overview ⇒ page 363
23 - Bolt
rrectness of i
❑ 20 Nm
l purpos
24 - Support
❑ For turbocharger
nf
ercia
or
25 - Bolt
m
m
atio
m
❑ 9 Nm
o
n in
or c
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26 - O-rings
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sd
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cu
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f
❑ Various diameters.
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ng
t.
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27 - Banjo bolt
C py
t. rig
gh ht
yri
❑ 40 Nm
p by
co Vo
by lksw
cted agen
28 - O-rings
Prote AG.

29 - Banjo bolt
❑ 30 Nm
30 - O-rings
31 - Nut
❑ 24 Nm
Tightening sequence and procedure

• Support ⇒ Item 24 (page 251) must be released on crankcase
and turbocharger.
♦ Position turbocharger ⇒ Item 9 (page 250) on studs on cylinder
head.
♦ Screw bolt ⇒ Item 23 (page 251) loosely into turbocharger.
♦ Tighten nuts -1- to -8- to 25 Nm in specified sequence. Then,
tighten nuts to 25 Nm again in the specified tightening se‐
quence.
♦ Tighten bolt ⇒ Item 23 (page 251) .

Caddy 2011 ➤
Installation position of intake hose at turbocharger

– Fit connecting hose in such a way that the “extension” -2- of
the connecting hose is in contact with the corner of the name‐
plate -2-.
Installation position of connecting hose

– Install connecting hose in such a way that marking -1- on con‐
necting hose is opposite marking -2- eon pulsation
n AG . Volkswagedamper.
n AG
wag does
olks not
byV gu
ara
ed nte
ris
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au ra
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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
Installation position of exhaust gas temperature sender with an‐
es, in part or in w
gled cable guide

t to the co
Note
rrectness of i
l purpos
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.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Installation position of O-ring and seal in pulsation damper

p
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 ➤
1 - Damper
❑ With grooves
2 - O-ring
3 - Sealing ring
❑ With spring
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
2.2 Removing and installing turbocharger

m
at
om
ion
c
in t
or
♦ Lambda probe open ring spanner set - 3337-
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 ➤
♦ Ratchet ring spanner - T10385- agen

AG. Volkswagen AG d
oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
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nl
pt
du
an
itte
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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
♦ Tool insert, AF 17 mm - T10395-
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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cu
o
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en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co
Caution
by lksw
cted agen
Prote AG.
If a mechanical fault is discovered on the turbocharger (e.g. a

destroyed compressor impeller), it is not sufficient to just renew
the turbocharger. To avoid any subsequent damage, the fol‐
lowing work must be carried out:
♦ 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
– Remove particulate filter ⇒ page 354 .

Caddy 2011 ➤
pipe ⇒ page 341 .
case.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
– Open heat shield
ss a gaiter -1- from charge pressure servo posi‐ c
ce
le
un
pt
an
d

itte
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erm

ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectnes
– Open bracket -2- and unhook vacuum hose -1-.

s o
cial p
f i
– Pull off vacuum hose -1- from vacuum unit on turbocharger.

nform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Disconnect electrical connector -1- for exhaust temperature

sender 3 - G495- and free electrical line.
– Carefully take the line out of the brackets on plenum chamber
bulkhead and on turbocharger.
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
– Unscrew bolt -1- from charge air pipe and undo the two clips
erm
ab
of the connecting hose.
ility
ot p
wit
, is n
– Remove pulsation damper.
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
– Take off pulsation damper -2-.
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.
– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
lation.
– Remove bevel box ⇒ Rep. gr. 34 ; Bevel box; Removing bevel
box .
– Remove oil lines on turbocharger and turbocharger support
⇒ page 198 .

Caddy 2011 ➤
– Unscrew bolts -arrows- and remove heatAshield.

G. Volkswagen
agen AG do
ksw es n
y Vol ot g
ua
b
ed ran
oris tee
th or
au ac
ss
ce
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un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
– Unscrew nuts -arrows-.
– Remove turbocharger together with exhaust manifold from
rrectne
cylinder head and turn so that the intake side is facing down‐
wards. Remove turbocharger together with exhaust manifold
s
downwards.
s o
cial p
f i
Installing
nform
mer
atio
om
n
c
i
or
n thi
Caution
te
sd
iva
o
pr
cum
r
Before installing, check whether flexible joint of oil return line

fo
en
ng
is bent and thus stretched. If this is the case, micro-fractures

t.
yi Co
op
may have been caused and this will cause leaks. If necessary, C py
t. rig
renew oil return line before installing turbocharger.
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Install turbocharger. Follow tightening sequence.
Note
♦ Renew seals, gaskets, O-rings and self-locking nuts.

♦ Fill turbocharger with engine oil at connection for oil supply
line.
♦ After installing turbocharger, run engine for about 1 minute at
idling speed to ensure that oil is supplied to turbocharger.
♦ Fit heat shield sleeves in the same place when installing.
– Install support for turbocharger with oil supply line. To do this,

tighten bolts -1,3-, union nut -2- and banjo bolts -4,5- to speci‐
fied torque.
– Install bevel box ⇒ Rep. gr. 34 ; Bevel box; Installing bevel
box .
– Install exhaust gas recirculation pipes ⇒ page 369 .
– Installing exhaust temperature sender 1 - G235-
⇒ page 364 .

Caddy 2011 ➤

– Connect vacuum hoses ⇒ page 279 .
On all-wheel drive vehicles, install right flange shaft ⇒ Running
gear, axles, steering; Rep. gr. 39 ; All-wheel drive - renewing
flange shaft seals; Renewing seal for right flange shaft .
Torque settings
♦ ⇒ “2.1 Assembly overview - turbocharger”, page 249
♦ ⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 369
♦ Drive shafts; Assembly overview - drive shafts ⇒ Rep. gr. 40 ;
Assembly overview - drive shaft .
2.3 Replacing vacuum unit with position

sender for charge pressure positioner -
G581-
♦ Torx bit T40 - T10422-
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
♦ Ring spanner 10 x 12 - T10423-

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
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Cop py
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Prote AG.

lkswage es n
o ot g
byV ua
d ran
ho
ir se tee Caddy 2011 ➤
t or
au 4-cylinder diesel engine (2.0 l engine, common
ac rail) - Edition 09.2016
ss
ce
e
nl
♦ Hand operated vacuum pump - VAS 6213-
pt
du
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itte
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ility
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es, in part or in w
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Caution
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for
The special tools indicated, in particular socket - T10422- or
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socket AF 10 mm - T10422 A- , are designed solely to be used Cop py
in accordance with the following procedures and must not be
t. rig
gh ht
yri
used for other threaded connections. There is a danger of de‐
p by
co Vo
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formation if high torques are applied. Prote
cted AG.
agen
Note
In order to change the vacuum unit with position sender for charge
pressure servo - G581- , a replacement parts kit is available ⇒
ETKA (Electronic Parts Catalogue) .
Removing
pipe ⇒ page 341 .
– Open heat shield gaiter -1- from charge pressure servo posi‐

Caddy 2011 ➤
case.
– Seal opening in turbocharger with sealing cap from replace‐
ment parts kit.

AG. Volkswagen AG d
agen oes
– Unscrew securing nut -arrow- where theVooil supply line/vac‐
lksw not
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uum line is connected to the cylinder
sedhead.
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Caution ss c
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When detaching the oil supply line, counterhold the connec‐

itte
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tion. Risk of damage as a consequence!

erm
ab
ility
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– Prepare a 14 mm open-ended wrench for counterholding.

ole,
spec
t to the co
14 mm tool for counterholding connection piece of oil supply line

rrectne
♦ A = 110 mm
s
♦ B = 25 mm
s o
cial p
f inform
mer
atio
om
n
c
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or
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Counterhold connection piece and unscrew oil supply line

-arrow- from turbocharger.
– Seal oil supply opening in turbocharger with plug from re‐
placement parts kit.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
ise n
– Counterhold thlock
or nut -B- with ring spanner - T10423- andteun‐ eo
screw securing
s au nut -A- from the control rod using socket inset ra
c
- T10422- .
s
ce
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nl
pt
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itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Unscrew securing bolts of the vacuum unit -arrows- and re‐
l purpos
move the vacuum unit -A-.

Installing
nf
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orm

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Caution
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Only use new nuts and bolts from replacement parts kit!
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Cop py
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– If necessary, remove lower securing nut of the control rod from
gh ht
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the new vacuum unit.
cop Vo
by lksw
cted agen
Prote AG.
– Screw locknut by hand onto the control rod as far as possible
in the direction of the vacuum unit.
– Push control rod through adjusting lever on turbocharger, fit

vacuum unit -A-, and tighten securing bolts hand-tight.
– Tighten securing bolts -arrows-.
Note
♦ Make sure that the guiding element moves easily along the
control rod.
♦ Because of its high degree of alloying, the securing nut is not
magnetic. A magnet can be used for support.
– Connect hand vacuum pump - VAS 6213- to vacuum unit.

Caddy 2011 ➤ gen AG
. Volkswagen AG
does
swa
4-cylinder diesel engine (2.0 l engine, common rail) - Edition
yV
olk 09.2016 not
gu b ara
ed nte
ris
– Fit securing nut by hand -A-. au
tho e or
ac
ss
– Allow partial vacuum to escape from the vacuum unit.
ce
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nl
pt
du
an
– Remove protective cap, fit oil supply line to turbocharger and
itte
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tighten.
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
– Fit connector -2- to position sender for charge pressure servo l purpos
- G581- -3-and close heat protection mat -1-.
nform
ercia

m
– Select Engine electronics on display.
at
om
ion
c
The display indicates the control unit identification and the coding
in t
or
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e
of the engine control unit.

at
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Selecting diagnostic function:
um
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– Click the 011 - Measured values button on the display.
Co
Cop py
ht. rig
– In the selection list, select “Positioner for high pressure, tur‐
rig ht
py by
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bocharger, actual input voltage” and switch until measured by c lksw
cted agen
value is displayed. Prote AG.
– Connect hand vacuum pump - VAS 6213- to vacuum unit.

– While observing the displayed measured value, set a voltage
of 760 mV by creating a vacuum of max. 0.65 bar.
Caution
During the following procedure for adjusting the control rod,

keep the partial vacuum and thus the voltage of 0.760 V con‐
stant.
– Slowly screw the locknut-B- of the control rod downwards by

hand. Adjusting lever rests against lower »stop«.
– Counterhold locknut-B- and screw securing nut-A- onto the
control rod towards the adjusting lever. Tighten slightly with a
ring spanner - T10423- .
– Allow partial vacuum to escape from the vacuum unit.
– Observe the lowest value of the measured value block. When
there is no pressure, the value should be 3.00 to 3.40 V.
– Fit socket inset - T10422- , counterhold locknut -B- with ring
spanner - T10423- and tighten securing nut -A-.
Caution
Create a partial vacuum of 0.65 ± 0.05 bar to act on the vacuum

unit in order to ensure that the adjusting lever rests against the
»stop«. When this is done, the voltage should automatically be
set to 0.760 V.
Voltage OK.

Caddy 2011 ➤
– Press locking plate by hand onto the control rod and, if possi‐
ble, turn 90° in the -direction of the arrow-.
– Seal connection between control rod/securing nut with sealing
paint from replacement parts kit.
Voltage not OK.
– Counterhold locknut -B-, undo securing nut -A- of the control

rod and correct the voltage by turning the locknut -B-.
– Counterhold locknut -B-, turn securing nut -A- in opposing di‐
rection and tighten it with socket inset - T10422- .
AG. Volkswagen AG d
agen oes
olksw not
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– Press locking plate by hand onto the control rod oris and, if possi‐
e nte
eo
ble, turn 90° in the -direction of the arrow-.auth ra
ss c
– Seal connection between control rod/securing nut with sealing
ce
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nl
pt
paint from replacement parts kit.
du
an
itte
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erm
Continuation
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ility
ot p
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hole
spec
es, in part or in w
t to the co
– Fit vacuum hose -1- to vacuum unit on turbocharger. rrectness of i
l purpos
– Engage vacuum hose -1- and close bracket -2-.

nf
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orm
m
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om
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Cop py
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rig ht
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by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Fit securing nut -arrow- connecting the oil supply line/vacuum

line to the cylinder head and tighten it.
– Remove sealing cap from turbocharger.
– When mounting intake connecting pipe on .turbocharger, it

must be ensured that intake connecting AG Volkswagen AG dseat‐
swagen pipe is correctly oes
k
ed on the bolt of the turbocharger.
by
Vol -arrow-.
not
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ise
– Re-install all engine components.
tho
r tee
or
u ac
sa
– Start engine, and clear
s event memory ⇒ Vehicle diagnostic
ce
le
tester.
un
pt
an
d
itte
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– Check setting as follows:
erm
ab
ility
ot p
Selecting diagnostic function:
wit
is n
h re
– Click the button 006 - Basic setting on the display.
ole,
spec
– Select Adaptation of turbocharger from selection list.
t to the co
– Click the button Measured values on the bottom right on the
display.
rrectne
– Select Positioner for high pressure, turbocharger,
actual input voltage from selection list.
ss o
– Click the Start button on the bottom right on the display.

cial p
f inform
– Observe value in lower part of screen. Value must fluctuate

mer
atio
between 0.65 ... 0.85 V and 3.00 ... 3.40 V (vacuum unit is
om
moved to both end stops alternately).

n
c
i
or
n thi
e
If voltage values are OK:

t
sd
iva
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pr
cum
– End basic setting procedure.

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fo
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ng
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Torque settings
Co
Cop py
t. rig
gh ht
♦ ⇒ “2.1 Assembly overview - turbocharger”, page 249 yri
p by
co Vo
by lksw
cted
agen
Prote AG.

Securing bolts for vacuum unit 8 Nm
2.4 Removing and installing charge pres‐

sure control solenoid valve - N75-

Caddy 2011 ➤
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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ce
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un
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d
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rm
ab
pe
ility
ot
Removing
wit
, is n
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hole
spec
case.
es, in part or in w
t to the co
– Unclip vacuum hoses -arrows- and place to one side.
– Remove intake hose -3- on air filter.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
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fo
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t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Pull off vacuum hoses -4-, -5- and -6- from charge pressure
control solenoid valve - N75- -2-.
– Release connector -1- and pull off.
– Unscrew nuts -3- and remove charge pressure control sole‐
noid valve - N75- -2-.
Installing
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.
– Install suction hose on turbocharger ⇒ page 239 .
– Tighten nuts -3-.
– When fitting intake connectingswpipe AG. Volkswagen AG densure

agen to turbocharger, oes
that intake connecting pipe
by V is correctly seated on stud of tur‐
o lk not
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bocharger. -arrow-. rised ara
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tho or
Specified torque s au ac
s
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nl

pt
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Nuts for charge pressure con‐ 6 Nm

erm
ab
trol solenoid valve - N75-

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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Cop py
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by lksw
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Prote AG.

Caddy 2011 ➤
23 – Mixture preparation - injection

1 Injection system
⇒ “1.1 Schematic overview - fuel system”, page 267
⇒ “1.2 Overview of fitting locations - injection system”,
page 269
⇒ “1.3 Checking fuel system for leaks”, page 277
⇒ “1.4 Filling and bleeding fuel system”, page 277
1.1 Schematic overview - fuel system
WARNING
AG. Volkswagen AG d
agen oes
lksw not
♦ Read through the rules for cleanliness and d bythe instructions
Vo gu
ara
for working on the fuel system ⇒ page oris 7 .
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♦ Always follow these rules for cleanliness
ss a and instructions c
before starting work and while working on the fuel system.
ce
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nl
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♦ If components of the fuel system between the tank and the
itte
y li
high-pressure fuel pump are removed or renewed, the fuel
erm
ab
ility
system must be filled to be bled ⇒ page 277 . (It is im‐
ot p
wit
portant not to allow the high-pressure pump to run while
, is n
h re
still empty.)
hole
spec
es, in part or in w
t to the co
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:
rrectness of i
♦ If fuel system components between fuel tank and fuel high-
l purpos
pressure pump are removed or renewed;

♦ If the fuel pump - G6- , a fuel line or the fuel filter is removed
nf
ercia
or replaced
orm
m
♦ If the fuel high-pressure pump is removed or replaced atio

om
n in
or c

thi
te
sd
iva
– Carry out function Fill/bleed high-pressure pump/fuel

o
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cu
o
system ⇒ Vehicle diagnostic tester.

f
en
ng
t.
yi Co
op
The diesel direct injection system control unit is equipped with an C py
t. rig
event memory. Read event memory before and after making re‐
gh ht
pyri by
pairs or adjustments.
o Vo
by c lksw
cted agen
Prote AG.
1. Injection system 267

Caddy 2011 ➤
1 - Fuel tank
❑ With fuel system pres‐
surisation pump - G6- .
2 - fuel filter.
❑ With pre-heating valve.
❑ Assembly overview -
fuel filter ⇒ Fuel supply;
Rep. gr. 20 ; Fuel filter;
Assembly overview - AG. Volkswagen AG d
fuel filter . agen oes
olksw not
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❑ Removing and installing ised b ara
nte
⇒ Fuel supply; Rep. gr. ut
hor eo
20 ; Fuel filter; Remov‐ ss a ra
c
ing and installing fuel fil‐
ce
le
un
ter .
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itte
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3 - Supplementary fuel pump -
erm
ab
V393-
ility
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is n
Removing and installing ⇒
h re
ole,
Fuel supply system; Rep. gr.
spec
20 ; Supplementary fuel pump

- V393- ; Removing and instal‐
t to the co
ling supplementary fuel pump -
V393-
rrectne
4 - Filter strainer
s
5 - Fuel temperature sender -
s o
G81-
cial p
f inform
6 - High-pressure pump
mer
atio
❑ After renewing, a first
om
n
fuel filling must be per‐
c
i
or
n thi
formed (never allow the
te
sd
a
pump to run while it is

iv
o
pr
c
still empty)
um
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fo
en
ng
⇒ page 277 . yi
t.
Co
op
C py
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⇒ page 317 rig ht
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7 - Fuel metering valve - N290-
cted agen
Prote AG.
❑ Must not be removed.
8 - Fuel pressure regulating valve - N276-
❑ Installing and removing ⇒ page 330
9 - High-pressure accumulator
❑ After renewing, a first fuel filling must be performed (never allow the pump to run while it is still empty)
⇒ page 277 .
10 - Fuel pressure sender - G247-
11 - Pressure retention valve
❑ The pressure retention valve maintains a residual pressure of approx. 10 bar in the return lines.
❑ This residual pressure is required for the control function of the injectors
❑ The pressure retention valve may only be renewed completely together with the fuel return lines.
❑ After renewal, engine must be run at idling speed for approx. 2 minutes to bleed fuel system.
12 - Injectors
❑ Injector, cylinder 1 - N30-
268 Rep. gr.23 - Mixture preparation - injection

Caddy 2011 ➤
1.2 Overview of fitting locations - injection

system
Components from “A” to “I” are not shown in the illustration.
lkswage es n
1 - Supplementary fuel pumpb-y Vo ot g
ua
V393- ir se
d ran
tee
ho
❑ Assembly overviewaut
⇒ or
ac
ss
Fuel supply; Rep. gr.
ce
e
20 ; Supplementary fuel
nl
pt
du
an
pump - V393- ; Assem‐
itte
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bly overview Supple‐
erm
ab
mentary fuel pump -
ility
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V393-
wit
, is n
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hole
spec
⇒ Fuel supply; Rep. gr.
es, in part or in w
20 ; Supplementary fuel
t to the co
pump - V393- ; Remov‐
ing and installing sup‐
plementary fuel pump -
rrectness of i
V393- .
l purpos
2 - Exhaust gas pressure sen‐

sor 1 - G450-
nform
ercia
⇒ page 363
m
at
om
❑ Adaptation is necessary ion

c
in t
after this component
or
his
e
has been renewed

at
do
priv

um
for
⇒ page 327
en
ng
t.
yi Co
op
3 - Hall sender - G40- (cam‐
C py
t. rig
gh
shaft position sensor)
ht
pyri by
Vo
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by
❑ Fitting location Prote
cted AG.
agen
⇒ page 274
❑ Electrical connection for
Hall sender - G40-
⇒ page 274
❑ 10 Nm
4 - Injectors

Caddy 2011 ➤
⇒ page 288
5 - Engine (motor) control unit - J623-
❑ Fitting location ⇒ page 272
6 - Lambda probe - G39- with Lambda probe heater - Z19-
7 - Position sender for charge pressure positioner - G581-
8 - Exhaust gas recirculation actuator - V338- with exhaust gas recirculation potentiometer - G212- .
❑ Integrated in exhaust gas recirculation cooler
10 - Charge pressure control solenoid valve - N75-
❑ Fitting location of connector ⇒ page AG275
. Volkswagen AG
agen does
❑ Removing and installingy⇒ olksw 264
page not
V gu b ara
ed
11 - Electrical connector horis nte
e
t or
❑ For exhaust gas au
ss temperature sender 3 - G495-
ac
ce
le
❑ For exhaust gas temperature sender 1 - G235- .

un
pt
an
d
❑ For Lambda probe - G39- .

itte
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rm
ab

pe
ility
ot
wit
12 - Air mass meter - G70-

, is n
h re
hole

spec
es, in part or in w

t to the co

rrectness of i

l purpos
14 - Engine speed sender - G28-

nform
ercia

m
a
com
ti
15 - Exhaust gas recirculation cooler changeover valve - N345-

on in
r
te o

thi
s
iva
do
16 - Pump for exhaust gas recirculation cooler - V400-

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fo

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ng
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17 - Throttle valve control module - J338- with throttle valve potentiometer - G69-
C py
t. rig
gh ht
yri
p by
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cted
agen
Prote AG.
18 - Glow plugs
❑ Glow plug 1 - Q10-

Caddy 2011 ➤
19 - Fuel temperature sender - G81-

❑ In fuel supply line
20 - Charge air pressure sender - G31- with intake air temperature sender - G42-
21 - High-pressure pump with fuel metering valve - N290- .
❑ Do not open fuel metering valve - N290-
❑ After renewing, initial fuel filling must be carried out (never allow pump to run dry) ⇒ page 277 .
22 - Fuel pressure sender - G247-
23 - Radiator outlet coolant temperature sender - G83-
24 - fuel filter.
❑ Assembly overview ⇒ Fuel supply; Rep. gr. 20 ; Fuel filter; Assembly overview - fuel filter
❑ Renewing ⇒ Fuel supply;wRep.
agen gr. 20 ; FuelAfilter;
AG. Volkswagen G d
oes Removing and installing fuel filter
ks not
Vol gu
A - Fuel system pressurisation
ed
by pump - G6- ara
nte
ris
❑ Fitting location
uth⇒ page 273
o eo
ra
a c
ss
B - Low heat output relay - J359- and high heat output relay - J360-
ce
e
nl
pt
du
❑ Fitting location ⇒ Current flow diagrams, Electrical fault finding and Fitting locations
an
itte
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ab
C - Brake light switch - F- and brake pedal switch - F47-

ility
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❑ In footwell on brake pedal

wit
, is n
h re

hole
spec
D - Clutch position sender - G476-

es, in part or in w
t to the co

❑ Only fitted to vehicles with a manual gearbox
rrectness of i
E - Accelerator position sender - G79- and accelerator position sender 2 - G185-

l purpos

❑ Removing and installing ⇒ Fuel supply; Rep. gr. 20 ; Electronic power control (EPC); Accelerator module
wit accelerator position sender -G79-
nform
ercia
F - Exhaust gas temperature sender 1 - G235-

m
at
om
io

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in t
or

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ate
do
priv
G - Exhaust gas temperature sender 3 - G495-

um
for
en
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❑ Electrical connector for exhaust temperature sender 3 - G495- ⇒ page 275

n
t.
yi Co
op py
❑ Assembly overview ⇒ page 363 t. C rig
gh ht
yri by
❑ Removing and installing ⇒ page 365 cop Vo
by lksw
cted agen
Prote
H - Exhaust gas temperature sender 4 - G648-
AG.

I - particulate filter
❑ Component shared with catalytic converter
❑ Adaptation is necessary after this component has been renewed

Caddy 2011 ➤
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.
Removing and installing ⇒ page 343 .
AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
Location of accelerator position sender - G79- and accelerator
hor eo
position sender 2 - G185- aut ra
ss c
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nl
pt
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an
itte
Note
y li
erm
ab
ility
ot p
The accelerator pedal position sender - G79- and accelerator
wit
, is n
pedal position sender 2 - G185- are integrated in the accelerator
h re
pedal module and cannot be replaced singly.
hole
spec
es, in part or in w
t to the co
Removing and installing ⇒ Fuel supply; Rep. gr. 20 ; Electronic
power control (EPC); Accelerator module wit accelerator position
sender -G79-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
e
Brake light switch - F- and brake pedal switch - F47- -1-

at
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c
♦ On main brake cylinder.
um
for
en
ng
t.
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Integrated functions: Clutch pedal switch for engine starting -
Co
op py
F194- and clutch pedal switch - F36- (only in the case of manual
t. C rig
gh ht
yri
gearboxes) p by
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by c lksw
cted agen
Removing and installing ⇒ Rep. gr. 47 . Prote AG.

Caddy 2011 ➤
Location of clutch position sender - G476-

♦ On clutch sender cylinder -arrow-.
Integrated functions: Clutch pedal switch for engine starting -
F194- and clutch pedal switch - F36- (only in the case of manual
gearboxes)
Removing and installing ⇒ Rep. gr. 30 .
Fuel system pressurisation pump - G6-

Removing and installing or
Location of pump for exhaust gas recirculation

swa
gen AG
. Volkcooler - V400-
swagen AG
does
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Vol gu
2 - Pump for exhaust gas recirculation
se
db
y
cooler - V400- ara
nte
o ri eo
♦ On front of engine auth ra
ss c
Assembly overview ⇒ page 228
ce
le
un
pt
an
d
itte
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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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o
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cum
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fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
Location of charge air pressure sender - G31- with intake air tem‐
perature sender - G42-
1- Charge air pressure sender - G31- with intake air tempera‐
ture sender - G42-
♦ On air pipe on right
Fitting location of Hall sender - G40-

♦ Next to toothed pulley of camshaft -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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ce
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nl
pt
Connector -1- for Hall sender - G40-

du
an
itte
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erm
ab
ility
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wit
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
Components for exhaust gas recirculation on rear of engine

orm
m
2 - Exhaust gas recirculation actuator - V338- with exhaust gas

atio
m
recirculation potentiometer - G212- .

o
n in
or c
thi
e
4 - Vacuum servo element for exhaust gas recirculation cooling

t
sd
iva
system
o
r
rp
cu
o
m
f
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Installation locations and plug-in connections

1- Electrical connector for exhaust temperature sender 3 -
G495-
G235-
3- Electrical connector for Lambda probe - G39-
1 - Electrical connector for charge pressure control solenoid valve
- N75-
Location and connector

G648- AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
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un
pt
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itte
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ab
pe
ility
ot
wit
, is n
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hole
spec
Charge pressure control solenoid valve - N75- -2-
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
Location of fuel temperature sender - G81- cum

fo
en
ng
t.
yi Co
4 - Fuel temperature sender - G81- t. Cop py
rig
gh ht
yri
♦ In fuel supply line at high-pressure pump. p by
o Vo
by c lksw
cted agen
Prote AG.

Caddy 2011 ➤
Location of coolant temperature sender - G62-

♦ at right of engine, under vacuum pump.
AG. Volkswagen AG d
agen oes
ksw
Location of radiator outlet coolant temperature sender by V - G83-
ol not
gu
d ara
ise nte
2 - Radiator outlet coolant temperature sender hor- G83- eo
aut ra
c
♦ In coolant pipe on right above the alternator.
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
Location of position sender for charge pressure servo - G581-
rrectness of i
-3-
l purpos
♦ On rear of engine on top of turbocharger.
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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rp
cu
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en
ng
t.
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Cop py
ht. rig
rig ht
by
Location of exhaust gas recirculation cooler changeover valve - copy Vo
by lksw
N345- -3- cted agen
Prote AG.
♦ On front left of intake manifold.

Caddy 2011 ➤
Location of engine speed sender - G28-

1- Engine speed sender - G28-
2- Sender wheel
♦ On flywheel side of engine.
Components on engine
1- Exhaust gas pressure sensor 1 - G450-
2- Exhaust gas temperature sender 3 - G495-
3- Lambda probe - G39-
4- Position sender for charge pressure positioner - G581-
5- Injectors (N30 to N33)
6- Glow plugs (Q10 to Q13)
7- Fuel pressure sender - G247-
1.3 Checking fuel system for leaks

– Clean all removed and re-installed fuel connections with brake
cleaner and then dry them.
– Allow the engine to idle for 5 minutes without depressing the
accelerator pedal. Then, switch engine off. Fuel system will
bleed itself automatically.
AG. Volkswagen AG d
agen oes
– Check entire fuel system for leaks . Volksw not
gu
by ara
d
Renew the affected component if oleakage
ris
e
still occurs after tight‐ nte
eo
ening to the correct torque. auth
ra
ss c
– Then, road-test the vehicle for more than 20 km with full throttle
ce
e
nl
pt
du
acceleration at least once. Then check high-pressure section

an
itte
of fuel system again for leakage.

y li
erm
ab
ility
ot p
wit
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Note
h re
hole
spec
If there is still air in the fuel system, the engine can change to
es, in part or in w
t to the co
emergency running mode during road test. Switch off engine and
clear event memory. Then continue with a road test.
rrectness of i
1.4 Filling and bleeding fuel system

l purpos

nform

mercia
at
om
Caution
on
c
in t
or
his
te
After new or removed parts such as the fuel filter or fuel lines
a
do
riv
have been fitted, the high-pressure pump must be filled with

p
cum
or
fuel before the engine is started for the first time. It is essential
f
en
ng
t.
yi
not to allow the high-pressure pump to run while still empty.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
Note
♦ When installing the high-pressure pump, it is essential to en‐

sure that no dirt enters the fuel system.
♦ Only remove sealing plugs immediately prior to installation of
fuel lines.
♦ Vehicle must have fuel.
AG. Volkswagen AG d
agen oes
lksw n t
Proceed as followsbytoV fill high-pressure pump with ofuel.
o gu
ara
ed
is nte
– Switch onuthignition.
or eo
a ra
s c
– Connects ⇒ Vehicle diagnostic tester and, depending on soft‐
ce
le
ware version, perform guided function Bleed fuel system

un
pt
an
d
or Fill/bleed fuel system .

itte
y li
erm
ab
ility
ot p
wit
is n
Note
h re
ole,
spec
♦ The fuel pumps will now be actuated for a total of three mi‐
nutes. The process must not be terminated prematurely.
t to the co
♦ There could still be air bubbles in the fuel system after the
bleeding procedure.
rrectne
– Start engine and visually inspect fuel system for leaks.
ss o
cial p
f in
Caution
form
mer
atio
m
Do not carry out starting attempts for longer than 15 seconds.

o
n
c
If engine does not start, repeat bleeding process.

i
or
n thi
te
sd
iva
o
pr
cum
r
fo
– After filling fuel system and successfully starting engine, allow

en
ng
t.
it to run for a few minutes at a moderate speed. Switch off op
yi Co
engine.
C py
t. rig
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yri by
– Check fuel system for leaks.
op Vo
by c lksw
cted agen
Prote AG.
– Read out event memory and, if necessary, delete the event
memory entry.
Note
clear event memory. Then continue with a road test.
– Read event memory again.

Caddy 2011 ➤
4-cylinder diesel engine (2.0
en A
lGengine,
. Volkswacommon
gen AG rail) - Edition 09.2016
ag does
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y Vol gu
b ara
ed
2 Vacuum system thoris nte
eo
s au ra
c
⇒ “2.1 Connection diagram - vacuum system”,
s
page 279
ce
le
un
pt
⇒ “2.2 Checking vacuum system”, page 280
an
d
itte
y li
erm
ab
⇒ “2.2.1 Checking non-return valve and vacuum hoses”,
ility
ot p
page 281
wit
is n
h re
⇒ “2.2.2 Checking vacuum reservoir and vacuum hoses”,
ole,
spec
page 282
t to the co
⇒ “2.2.3 Checking exhaust gas recirculation cooler changeover
valve N345 and vacuum hoses”, page 283
⇒ “2.2.4 Checking exhaust gas recirculation cooler changeover
rrectne
valve”, page 284
s
⇒ “2.2.5 Checking charge pressure control solenoid valve N75
s o
and vacuum hoses”, page 285
cial p
f inform
⇒ “2.2.6 Checking vacuum unit on turbocharger and vacuum ho‐
mer
ses”, page 286
atio
om
n
c
2.1 Connection diagram - vacuum system
i
or
n thi
te
sd
iva
o
pr
cum
r
Caution
fo
en
ng
t.
yi Co
op py
Do not kink, twist or crush the vacuum lines when routing vac‐ t. C rig
gh ht
uum lines. This may cause breakdowns. pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Vacuum system 279

Caddy 2011 ➤
1 - Pressure canister
❑ On turbocharger.
❑ With position sender for
charge pressure posi‐
tioner - G581- .
2 - Charge pressure control
solenoid valve - N75-
⇒ page 264
3 - Silencer
4 - Air filter
5 - To brake servo
6 - Connection piece
❑ On vacuum pump
7 - Non-return valve
❑ Observe installation po‐
sition
cooler changeover valve -
N345-
9 - Cylinder head cover
❑ With vacuum reservoir.
10 - Vacuum unit
❑ For changeover for ex‐ agen
AG. Volkswagen AG d
oes
haust gas recirculationVolksw not
gu
y
cooler. sed b ara
n ri tee
ho
aut or
ac
ss
ce
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nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
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2.2 Checking vacuum system

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 ➤
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
Caution
itte
y li
rm
ab
pe
ility
Do not kink, twist or crush the vacuum lines when routing vac‐
ot
wit
uum lines. This may cause breakdowns.
, is n
h re
hole
Push all hoses onto stop or at least 10 mm onto the respective
spec
connection.
es, in part or in w
t to the co
2.2.1 Checking non-return valve and vacuum
rrectness of i
hoses
l purpos
Test sequence
nform
ercia
– Pull off vacuum hose -2- from connection. Seal open end of
hose with suitable plug from engine bung set - VAS 6122- .
m
a
com
tion in
r
te o
thi
Note
s
iva
do
r
rp
cum
fo
Do not use screws or threaded bolts.

en
ng
t.
yi Co
Cop py
– Pull off vacuum hose -1- from connection.
t. rig
gh ht
pyri by
Vo
co
– Connect hand vacuum pump - VAS 6213- to pulled-off end of
by lksw
cted agen
Prote
vacuum hose -1- and generate a partial vacuum of 0.6 bar.
AG.
– Observe pressure gauge of hand vacuum pump - VAS 6213-

for approx. 30 seconds.
• Vacuum must not drop.
If vacuum drops:
– Renew leaking vacuum hose or non-return valve.
If pressure does not drop:
– First pull vacuum hose off at hand vacuum pump - VAS 6213- .
If the non-return valve functions properly, a clear hiss is audible
when vacuum in vacuum hose is released.
– Reconnect vacuum hose to connecting piece and vacuum
pump.

Caddy 2011 ➤
2.2.2 Checking vacuum reservoir and vacuum

hoses
Test sequence
– Pull off vacuum hose -arrow- from connection.
– Connect hand vacuum pump - VAS 6213- to removed vacuum
hose -arrow- and generate a partial vacuum of 0.6 bar.
If vacuum drops:
– Pull off vacuum hose -2- from cylinder head cover -1-.
– Seal open end of hose with suitable plug from engine bung set
- VAS 6122- .
Note
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum

reservoir and generate a partial vacuum of 0.6 bar.
• Vacuum must not drop. AG. Volkswagen AG d
agen oes
olksw not
V gu
If vacuum drops: d by ara
rise nte
ho eo
– Renew vacuum hose. aut ra
c
ss
ce
e
nl
pt
du
an
itte
– Connect hand vacuum pump - VAS 6213- with vacuum hose

y li
erm
ab
from -VAS 6213- to cylinder head cover and generate a partial

ility
ot p
vacuum of 0.6 bar.

wit
, is n
h re

hole

spec
es, in part or in w

t to the co
If vacuum drops:
rrectness of i
– Renew cylinder head cover ⇒ page 117 .

l purpos

nform
ercia
If vacuum reservoir in cylinder head cover functions properly, a

m
at
clear hiss is audible when vacuum in vacuum hose is released.

om
ion
c
in t
– Reconnect vacuum hose to T-piece and cylinder head cover.

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 ➤
. Volkswagen AG
gen AG
2.2.3 Checking exhaust gas recirculation wa does
olks not
yV gu
cooler changeover valve - N345- ed and
b ara
ris nte
ho eo
vacuum hoses
t
au ra
c
ss
ce
e
Test sequence
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
If vacuum drops:
rrectness of i
– Unhook exhaust gas recirculation cooler changeover valve -
l purpos
N345- from bracket on intake pipe.
nf
ercia
orm
– Pull off vacuum hose -arrow- on bottom connection of exhaust
m
atio
m
gas recirculation cooler changeover valve - N345- .

o
n in
or c
thi
te
sd
a
- VAS 6122- .
iv
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Note ht. Cop py
rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum

If vacuum drops:
– Renew vacuum hose.
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 AG. Volkswagen AG d
agen oes
olksw not
– Unhook exhaust gas recirculation cooler changeoverd byV valve - gu
ara
N345- from bracket on intake pipe. orise nte
eo
h
ut ra
– Pull off vacuum hose -arrow- on middles connection of exhaust
s a c
gas recirculation cooler changeover valve - N345- .
ce
e
nl
pt
du
an
– Connect hand vacuum pump - VAS 6213- to removed vacuum 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
If vacuum drops:
– Raise vehicle.
rrectness of i
l purpos
– Pull off heat protection -2- from vacuum servo element.

– Pull off vacuum hose -1- from vacuum servo element.
nf
ercia
orm
m
atio
m
- VAS 6122- .
o
n in
or c
thi
te
sd
iva
o
Note
r
rp
cu
o
m
f
en
ng
t.
yi
Co
Cop py
ht. rig
rig ht
py by
– Connect hand vacuum pump - VAS 6213- to pulled-off vacuum co Vo
by lksw
cted
agen
Prote AG.

If vacuum drops:
from -VAS 6213- to vacuum servo element of exhaust gas re‐
circulation cooler changeover valve and generate a partial
vacuum of 0.6 bar.
If vacuum drops:
– Renew exhaust gas recirculation cooler.
– 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- .
- VAS 6122- .
Note AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
Do not use oris screws or threaded bolts.
e nte
eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
y li
rm
ab

pe
ility
ot
wit
, is n

h re

hole
spec

es, in part or in w
t to the co

rrectness of i
If vacuum drops:
l purpos

nform
ercia

m
a
com
from -VAS 6213- to bottom connection of charge pressure

tion in
control solenoid valve - N75- and generate a partial vacuum

r
te o
thi
of 0.6 bar.
s
iva
do
r

rp
cum
fo

en
ng
t.
yi Co
op
C py
t. rig
gh ht
yri by
If vacuum drops:
op Vo
by c lksw
cted agen
Prote AG.
– Renew charge pressure control solenoid valve - N75-
⇒ page 264 .
– Reconnect vacuum hose on T-piece and on charge pressure
control solenoid valve - N75- .

Caddy 2011 ➤

2.2.6 Checking vacuum unit on turbocharger

and vacuum hoses
Test sequence
case.
– Pull off vacuum hose -arrow- on middle connection ofG.charge

A Volkswagen AG d
pressure control solenoid valve - N75- . lksw
agen oes
n o ot g
yV ua
– Seal open end of hose with suitable plug ed from engine bung set
b ran
ris
- VAS 6122- . ut
ho tee
or
a ac
ss
ce
le
un
pt
Note
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 ➤

If vacuum drops:
from -VAS 6213- to vacuum unit on turbocharger and generate
a partial vacuum of 0.6 bar.
. Volkswagen AG
gen AG does
If vacuum drops:Volkswa not
y gu
db ara
– Replaceoristurbocharger ⇒ page 253 .
e nte
h eo
ut ra
If pressure
ss a does not drop: c
ce
e
nl
pt
du
an
itte
y li
– Reconnect vacuum hose on vacuum unit of turbocharger and

erm
ab
on charge pressure control solenoid valve - N75- .

ility
ot p
wit
, is n
h re

hole
spec

es, in part or in w

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

Caddy 2011 ➤
3 Injectors/high-pressure accumulator
(rail)
⇒ “3.1 Assembly overview - fuel rail and injectors”, page 288
⇒ “3.2 Adapting correction values for injectors”, page 290
⇒ “3.3 Testing injectors”, page 291
⇒ “3.4 Checking return flow rate of injectors with engine running”,
page 291
⇒ “3.5 Checking return flow rate of injectors at starter speed”,
page 294
⇒ “3.6 Checking for injectors sticking open”, page 295
⇒ “3.7 Checking low pressure fuel system”, page 297
⇒ “3.8 Removing and installing injectors”, page 298
⇒ “3.9 Removing and installing high-pressure lines”, page 304
⇒ “3.10 Removing and installing fuel rail”, page 309
⇒ “3.11 Removing and installing injector seal in cylinder head
cover”, page 313
3.1 Assembly overview - fuel rail and injectors
1 - Sealing ring
❑ In cylinder head cover
⇒ page 313 agen
AG. Volkswagen AG d
oes
olksw not
V gu
2 - Copper washer ed by ara
nte
ris
❑ Renew after uremoval
tho eo
ra
s a c
s
3 - O-ring
ce
le
un
pt

an
d
itte
y li
erm
ab
4 - Injector
ility
ot p
wit
is n
h re
WARNING
ole,
spec
Only cleaning set - VAS

6811- may be used for

t to the co
cleaning the sealing sur‐

face of the injector bore.
rrectne
For detailed information

on how to use the clean‐
s
ing set as well as the or‐

s o
der in which its compo‐

cial p
f in
nents are applied, refer

form
mer
to the ⇒ operating in‐

atio
structions provided with

om
the cleaning set - VAS

c
i
or
n thi
6811- .
te
sd
iva
o
pr
cum
r
fo
❑ When removing and in‐

en
ng
t.
yi
stalling, always renew
Co
op py
the following compo‐
t. C rig
gh ht
yri
nents and seals/O- p by
o Vo
by c
rings: “copper seal”, “O-
lksw
cted agen
Prote
ring for injector bore”,
AG.
“O-ring for injector re‐

turn connection”.

Caddy 2011 ➤
❑ The following components and seals/O-rings must always be renewed when an injector is renewed:
“clamping piece”, “copper seal”, “O-ring for injector shaft” and “O-ring for injector return connection”.
❑ Before re-using high-pressure lines, perform visual check of taper seats for damage, e.g. transverse
scores or corrosion. High-pressure line must always be agrenewed
en AG. V if damaged.
olkswagen AG
does
olksw no
❑ Injectors, high-pressure lines and clamping piecesdb
y V must only ever be refitted on tthegu same cylinder.
ara
ise nte
❑ Removing and installing ⇒ page 298 thor eo
au ra
c
5 - O-ring ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
❑ To fuel tank
wit
, is n
❑ Must not be kinked, damaged or blocked.
h re
hole
spec
❑ Do not dismantle.
es, in part or in w
❑ After renewal, engine must be run at idling speed for approx. 2 minutes to bleed fuel system. Then check
t to the co
fuel return lines for leaks.
7 - Bolt
rrectness of i
l purpos
❑ 8 Nm +270°
8 - Clamping piece
nform
ercia
❑ Injectors and clamping pieces must only ever be refitted on the same cylinder.
m
at
om
❑ When an injector is renewed, the clamping piece must be renewed at the same time.
ion
c
in t
r

o
his
ate
do
riv
9 - High-pressure line
p
cum
or
❑ Between fuel rail and injectors

f
en
ng
t.
yi Co
Cop py
Note
t. rig
gh ht
pyri by
Vo
o
by c lksw
♦ Observe cylinder-specific mark‐ cted agen
Prote AG.
ings if reusing high-pressure
lines.
♦ The high-pressure lines may be
re-used after the following
checks:
♦ Check taper seal of respective
high-pressure line for deforma‐
tion and cracks.
♦ The inside of the line must not be
deformed, constricted or dam‐
aged.
♦ Corroded lines should no longer
be used.
❑ Install so that component is not under tension
❑ 28 Nm
10 - Bolt
❑ 22 Nm
11 - High-pressure accumulator
12 - Fuel return hose
❑ 80 Nm
3. Injectors/high-pressure accumulator (rail) 289

Caddy 2011 ➤
14 - O-ring
15 - High-pressure line
❑ Between high-pressure pump and fuel rail
Note
♦ Observe cylinder-specific mark‐

lines.
checks:
tion and cracks.
aged.
be used.
❑ 28 Nm AG. Volkswagen AG d
agen oes
16 - Bolt olksw not
y V gu
d b ara
❑ 8 Nm orise nte
eo
th
u ra
17 - Fuel pressure sender - G247- ss a c
ce
le

un
pt
an
d
itte
❑ 100 Nm
y li
erm
ab
ility
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is n
18 - Grommet
h re
ole,
❑ In cylinder head cover
spec
t to the co
Clamping piece installation position
rrectne
• One clamping piece encompasses 2 injectors each.
• Thick part -arrow- of clamping piece points downwards.
ss o
cial p
f inform
mer
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om
n
c
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Cop py
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3.2 Adapting correction values for injectors
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
The function “injector delivery calibration” serves to correct the

injection rates for each cylinder of a common rail system individ‐
ually across the entire ignition map range.
The 7-digit adaptation values -1- (details in illustration are only an
example) are marked separately on each injector. The marked
values may consist of letters and/or numbers.
lkswage es n
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Top view of injector
ss
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1 - Checksum
pt
du
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itte
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2 - Data Matrix Code
erm
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ility
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3 - Part number
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After renewing an injector, the adaptation value must be written
hole
spec
into the engine control unit.
es, in part or in w
t to the co
After renewing the engine control unit, the “adaptation values for
the injectors” must be transferred to the new engine control unit.
The work procedure for the adaptation is described in ⇒ Vehicle
rrectness of i
diagnostic tester.
l purpos
Additionally check that “injector delivery calibration” values are

correctly entered for all the other injectors. Do not attempt to re-
nf
ercia
enter these values if the correct values are already stored in the or
engine control unit.
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3.3 Testing injectors

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There are 4 different methods for testing the injectors.
Co
Cop py
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♦ ⇒ “3.2 Adapting correction values for injectors”, page 290 yri
p by
co Vo
by lksw
cted
♦ ⇒ “3.4 Checking return flow rate of injectors with engine run‐
agen
Prote AG.
ning”, page 291
♦ ⇒ “3.5 Checking return flow rate of injectors at starter speed”,
page 294
♦ ⇒ “3.6 Checking for injectors sticking open”, page 295
3.4 Checking return flow rate of injectors

with engine running
Checking return flow rate of all injectors
Caution
Danger of functional impairment due to contamination/soiling

♦ Observe rules for cleanliness ⇒ page 7 .
– Remove engine cover panel ⇒ page 11 .

– Detach hose connection from fuel return line.

Caddy 2011 ➤ . Volkswagen AG
gen AGcommon rail)
4-cylinder diesel engine (2.0ollkengine, -dEdition
swa no 09.2016
oes
V t gu
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ed nte
– Use a clean plug -2- to seal ho open return connection.
ris
eo
aut ra
– Hold fuel return hose -1-
ss (added an extension to it if necessary) c
ce
le
in measuring vessel to measure total return flow.
un
pt
an
d
– Start engine and allow to idle for 2 minutes. itte
y li
rm
ab
pe
ility
• Specified amount in 2 minutes: 0 ml to 50 ml
ot
wit
, is n
– If the specifications are achieved, increase engine speed to
h re
hole
between 2000 and 2500 rpm for approx. 2 minutes, and then
spec
check the amount of fuel returned.
es, in part or in w
t to the co
• Specified amount in 2 minutes: less than 250 ml
rrectness of i
Note
l purpos
1000 ml is 1 litre.
nform
ercia
If more fuel is returned than the specified amount, one or more

m
a
injectors are defective. Checking return flow rate of each individ‐
com
tion in
ual injector.
r
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thi
Checking return flow rate of individual injectors
s
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n
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op py
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Prote AG.
♦ Return flow meter - VAS 6684-
Each injector normally has a relatively low return flow rate. If the
return flow rate of one injector is relatively high compared to those
of the other injectors, that injector is probably defective.
– Clean all return line connections (e.g. with standard commer‐
cially available cold cleaning solvent) before removing them.
– Dry all cleaned parts.

Caddy 2011 ➤
– Clamp off fuel return hose -arrow- using hose clamp up to

25 mm - 3094- .
– Pull return line connections off at injectors. To do this, press

bows -1- and -2- down and simultaneously pull release pin
upwards -arrow-.
Note
Adhere strictly to rules of cleanliness. No dirt must be allowed to

get into the disconnected fuel return lines or the open connections
on the injectors.
– Fit adapter C6 firmly onto return line connections of all 4 in‐

jectors. . Volkswage n AG n AG d
wage oe
– Connect hoses of return yflow
Vol meter -VAS 6684- to adapters.
ks s no
tg
b ua
ed ran
– Start engine and allow
ho
ris to idle for several minutes. tee
t or
au ac
ss
Caution
ce
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nl
pt
du
an
itte
y li
Risk of damage to injectors after return lines have been pulled

erm
ab
off.
ility
ot p
wit
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♦ Do NOT press the accelerator during this test; the engine

h re
must only run at idling speed.

hole
spec
es, in part or in w
t to the co
– When the engine is at operating temperature and running at

idling speed, the return flow rates at each of the 4 return lines
rrectness of i
must not differ by more than a small amount (example -1-).

l purpos
– If one injector has a significantly higher return flow rate than

the others (example -2-), it must be renewed ⇒ page 298 .
nform
ercia
Installing fuel return lines

m
at
om
ion
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Note
o
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ate
do
priv
Lubricate all seals with engine oil or assembly oil before installing.
um
for
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ng
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op
– Renew O-rings of all return line connections. C py
t. rig
gh ht
yri by
– Carefully press connections of return lines onto injectors. The op Vo
by c lksw
catch should engage audibly. Then press release pin down cted agen
Prote AG.
carefully.
– Perform a leakage test on the fuel system ⇒ page 277 .

Caddy 2011 ➤
3.5 Checking return flow rate of injectors at

starter speed
If the engine cannot be started, the return flow rate of the injectors
can also be checked at starter motor speed.
♦ Return flow meter - VAS 6684-
lkswage es n
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byV ua
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ir se tee
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a ac
ss
ce
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nl
pt
du
an
itte
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erm
ab
ility
Caution
ot p
wit
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Danger of functional impairment due to contamination/soiling
hole
spec
es, in part or in w
♦ Observe rules for cleanliness ⇒ page 7 .
t to the co
Each injector normally has a relatively low return flow rate. If the
rrectness of i
return flow rate at one injector is relatively high compared to the
return flow rate of the other injectors, that injector is probably de‐
l purpos
fective.
nform
ercia
– Clean all return line connections (e.g. with standard commer‐

m
at
om
i
cially available cold cleaning solvent) before removing them.
on
c
in t
or

his
ate
do
riv
– Pull return line connections off injectors. To do this, press tabs

p
cum
for
-1- and -2- down and simultaneously pull release pin upwards
en
ng
t.
yi
-arrow-.
Co
Cop py
t. rig
gh ht
pyri by
Vo
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by
Note Prote
cted AG.
agen
Adhere strictly to rules of cleanliness. No dirt must be allowed to

get into the disconnected fuel return lines or the open connections
on the injectors.

Caddy 2011 ➤
– Detach electrical connector -arrow- from fuel pressure regu‐

lating valve - N276- .
Note
This prevents the fuel from being injected during the attempt at
starting.
– Fit adapter C6 firmly onto return line connections of all 4 in‐

jectors.
– Connect hoses of return flow meter -VAS 6684- to adapters.
– Activate starter 3 times (pausing for around 20 seconds after
each starting attempt to ensure that starter does not overheat).
• Return flow rate specification: 0 ml
– If fuel escapes from an injector, that injector has to be renewed
⇒ page 298 .
– Re-attach electrical connector of fuel pressure regulating
valve - N276- .
Installing fuel return lines n AG. Volkswagen AG do
lkswage es n
– Carefully press connections of return lines onto binjectors.
yV
o The ot g
ua
catch should engage audibly. Then press release ir se
d
pin down ran
tee
o
carefully. auth or
ac
ss
– Checking fuel system for leaks ⇒ page 277 .
ce
e
nl
pt
du
an
– Delete event memory entry with an ⇒ Vehicle diagnostic test‐
itte
y li
er.
erm
ab
ility
ot p
wit
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3.6 Checking for injectors sticking open
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
op
♦ Tool insert, 17 mm - V.A.G 1331/6- C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

lkswage es n
Caddy 2011 ➤ byV
o ot g
ua
ed ran
4-cylinder diesel engine (2.0 l hengine,
oris common rail) - Edition 09.2016 tee
ut or
a ac
ss
♦ Plug - T40204-
ce
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nl
pt
du
an
itte
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erm
ab
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
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WARNING
or
thi
te
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iva
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♦ Read through the rules for cleanliness and the instructions

rp
cu
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for working on the fuel system ⇒ page 7 .
f
en
ng
t.
yi Co
op
♦ Always follow these rules for cleanliness and instructions
C py
t. rig
gh
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
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.
Procedure
– Clear event memory entry using ⇒ Vehicle diagnostic tester.
– Before removing, clean the parts thoroughly all over with brake
cleaner and fluff-free cloth.
– Ensure cleanliness at all times.
– Check one cylinder after the other.
Begin with cylinder 1.
– Unscrew union nut for cylinder 1 on fuel rail. Also, loosen the
union nut at the injector a little.
– Seal the open connection with screw plug - T40204- .
• The electrical connector of the respective injector to be
checked must remain connected.
– Clear all event memory entries.
– Carry out road test.

Caddy 2011 ➤
Note
♦ When the correct injector has been located, there will be no

fault stored regarding “positive regulation deviation”.
♦ Other fault messages may possibly be stored in the memory.
– After road test, read out event memory. If there is an event

memory entry regarding “positive control deviation” again, re‐
peat the steps for all connections until there are no longer any
event memory entries after a road test.
Note installation instructions for all injector lines.
– Tighten union nuts of high-pressure lines hand-tight. Make
sure they are seated stress-free.
– Install high-pressure lines
agen ⇒ page 304 .AG do
AG. Volkswagen
w es n
olks ot g
Torque settings ed by V ua
ran
ris tee
tho
♦ ⇒ “3.1 Assembly overview - fuel rail and injectors”, page or288
au ac
ss
3.7 Checking low pressure fuel system
ce
le
un
pt
an
d
itte

y li
rm
ab
pe
ility
♦ K-Jetronic pressure tester - V.A.G 1318-
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
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cum
fo
Test conditions:
en
ng
t.
yi Co
op
• Battery voltage at least 12.5 V.
C py
t. rig
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• Fuel filter OK.
p by
co Vo
by lksw
cted agen
•
Prote
Fuel tank at least 1/2 full.
AG.
• Ignition switched off

Checking holding pressure
WARNING

♦ Wrap a clean cloth around the connection before opening
the fuel system, then carefully loosen the connection to
release the pressure.

Caddy 2011 ➤
– Remove fuel supply line -arrow- from high-pressure pump; re‐

lease hose clip for this.
– Connect K-Jetronic pressure tester - V.A.G 1318- with suitable

adapter -2- to fuel supply line -1-.
– Connect second hose -3- to -V.A.G 1318- at open connection
of high-pressure pump as shown in following illustration.
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
Note
ab
ility
ot p
wit
, is n
The K-Jetronic pressure tester - V.A.G 1318- must be inserted as
h re
an intermediate element into the fuel supply line.
hole
spec
es, in part or in w
t to the co
– Switch on ignition.
rrectness of i
– Choose Engine electronics and then Basic setting and
Check fuel system pressurisation pump .
l purpos
– Run fuel pumps until highest fuel pressure has built up.
nform
ercia
• Specification: at least 3.5 bar

m
at
om
If specification is not obtained

ion
c
in t
or
♦ Threaded connection between pressure tester and fuel line is

his
ate
leaking.
do
priv
cum
or
♦ Pressure tester leaking.

f
en
ng
t.
yi Co
op
♦ Fuel lines and their connections leaking. C py
t. rig
gh ht
yri
♦ Fuel filter is blocked.
p by
co Vo
by lksw
cted agen
– Check fuel pump delivery rate.
Prote AG.
Note
Check fuel system for leaks.
3.8 Removing and installing injectors


Caddy 2011 ➤
♦ Puller - T10055-
♦ Assembly sleeve - T10377-
lkswage es n
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byV ua
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ir se tee
tho
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♦ Socket - T40055- ss
ce
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un
pt
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d
itte
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rm
ab
pe
ility
ot
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Puller - T10415-
nform
ercia

m
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com

ion in
r
te o
Removing
thi
s
iva
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fo
WARNING
en
ng
t.
yi Co
op py
t. C rig
gh ht
yri
for working on the fuel system ⇒ page 7 . p by
co Vo
by lksw
cted agen
♦ Always follow these rules for cleanliness and instructions Prote AG.

♦ The open connections must be sealed immediately with a
suitable cap.
♦ Identify cylinder numbers on injectors. Injectors must al‐
ways be re-installed on the same cylinders.

Caddy 2011 ➤
– Pull return line connections off at injectors. To do this, press

bows -1- and -2- down and simultaneously pull release pin
upwards -arrow-.
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
– Detach electrical connectors -arrows- from injectors.
h re
hole
spec
es, in part or in w
Caution
t to the co
When releasing high-pressure line, counterhold high-pressure
connection using an open-ended spanner. Leaks occur if high-
rrectness of i
pressure connection is released.
l purpos
– Unscrew union nuts of relevant high-pressure line -1 to 4- and
nf
ercia
o
remove corresponding high-pressure line. Ensure cleanliness
rm
and adhere to prescribed procedure ⇒ page 304 .
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
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‐
inder 2, then for cylinder 1/cylinder 4, and then for cylinder 3.
– Fit puller - T10055- with puller - T10415- .

– Detach injector by tapping with puller - T10055- .
– Repeat process for second injector.
– Remove clamping piece together with injectors.
Note
AG. Volkswagen AG d
agen oes
lksw not
Pull injector out using rotary movements in order not to damage by
Vo gu
ara
sealing lip. ed
ris nte
ho eo
aut ra
s c
– Place removed parts on a clean, fluff-free surface and cover s
ce
le
them.
un
pt
an
d
itte
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Installing
rm
ab
pe
ility
Important instructions for installing injectors
ot
wit
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h re
• When removing and installing, always renew the following
hole
spec
components and seals/O-rings: “copper seal”, “O-ring for in‐
es, in part or in w
jector bore”, “O-ring for injector return connection”.
t to the co
renewed when an injector is renewed: “clamping piece”, “cop‐
rrectness of i
per seal”, “O-ring for injector shaft” and “O-ring for injector
return connection”.
l purpos
• Lubricate all O-rings with engine oil or assembly oil before in‐
stalling.
nform
mercia
a
com
t
Note
ion in
r
te o
♦ Observe cylinder-specific markings if reusing high-pressure thi

s
iva
do
lines.
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rp
cum
fo
en
g
♦ The high-pressure lines may be re-used after the following

n
t.
yi Co
op
checks: C py
t. rig
gh ht
yri
♦ Check taper seal of respective high-pressure line for defor‐
p by
o Vo
by c lksw
mation and cracks. Prote
cted AG.
agen
♦ The inside of the line must not be deformed, constricted or

damaged.
♦ Corroded lines should no longer be used.
If a used injector is being re-installed:

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
agen oes
olksw not
– Fit new copper sealing ring -1- on injector -2- with help of as‐ d by V gu
ara
sembly sleeve - T10377- . Use “narrow” side of assembly rise nte
ho eo
sleeve - T10377- for this. s aut ra
c
s
ce
le
un
pt
an
d
Note
itte
y li
rm
ab
pe
ility
Lubricate all O-rings with engine oil or assembly oil before instal‐
ot
wit
ling.
, is n
h re
hole
spec
– Carefully slide new O-ring over fuel return connection to avoid
es, in part or in w
t to the co
damaging O-ring.
– Clean sealing surface of injector in cylinder head and injector
shaft.
rrectness of i
l purpos
WARNING
nform
ercia
Only cleaning set - VAS 6811- may be used for cleaning the
sealing surface of the injector bore.
m
a
com
tio
For detailed information on how to use the cleaning set as well
n in
r
as the order in which its components are applied, refer to the

te o
thi
⇒ operating instructions provided with the cleaning set - VAS
s
iva
do
r
6811- .
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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 ➤
– Renew seal -1- for injector bore using assembly sleeve -

T10377- . gen AG
. Volkswagen AG
d
wa oes
olks not
– Push clamping piece onto injectors. byV gu
ara
ed nte
ris
– Insert injectors with clamping piece
tho into injector bores without eo
au ra
exerting excessive force. ss c
ce
e
nl
– Tighten bolts of clamping pieces to specified torque.
pt
du
an
itte
y li
– Apply a thin coat of diesel fuel to new O-rings on return-line
erm
ab
connections.
ility
ot p
wit
, is n
– Carefully push the connections of the return lines over the O-
h re
ring. You should hear them click into place. Then, carefully
hole
spec
press the release pin downwards.
es, in part or in w
t to the co
– Install high-pressure lines ⇒ page 304 .
rrectness of i
After one or more injectors have been renewed, the “injector de‐
l purpos
livery calibration” must be carried out for new injectors, and result
values must be entered into engine control unit ⇒ Vehicle diag‐
nostic tester.
nform
ercia
Additionally check that “injector delivery calibration” values are

m
at
om
i
correctly entered for all the other injectors. Do not attempt to re-
on
c
enter these values if the correct values are already stored in the
in t
or
his
e

at
do
priv
c
– Bleed fuel system ⇒ page 277 .
um
for
en
ng
t.
yi Co
Cop py
t. rig
Note gh ht
pyri by
Vo
co lksw
by
cted agen
♦ The high-pressure connections must not be opened for bleed‐ Prote AG.
ing.
♦ The return lines can only be renewed together with the pres‐
sure retention valve as one unit.
– Start engine and run at idling speed for a few minutes and then
switch off again.
– Switch off ignition.
– Check the complete fuel system and return line connections
(4 connections) for leaks ⇒ page 277 .
Renew the affected component if leakage still occurs after tight‐
ening to the correct torque.
Note
clear event memory. Carry out road test.
Torque settings

Bolt for clamping piece 8 Nm +270°

Caddy 2011 ➤
3.9 Removing and installing high-pressure

lines
♦ Ratchet wrench - V.A.G 1331/1-
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
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
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m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
304
cted agen
Prote AG.
Rep. gr.23 - Mixture preparation - injection
Caddy 2011 ➤
♦ Socket - T40055-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
rrectness of i
♦ The fluff-free cloth and the brake cleaner can be ordered in ⇒
ServiceNet; Workshop Equipment; Techno Equipment Cata‐
l purpos
logue; BMK Consumables .
nf
♦ Whenever work is done on the fuel system, ensure cleanliness
ercia
o
and do the work carefully. The fuel system reacts sensitively
rm
m
atio
to the ingress of dirt.
om
n in
or c
thi
e
Removing
t
sd
iva
o
r
rp
cu
o
m
f
Caution
en
ng
t.
yi Co
Cop py
t. rig
To position injection lines more easily and stress-free, loosen yri
gh by
ht
fuel rail and injectors and shift slightly. The lines must never be cop Vo
by lksw
bent or tensioned. Tension would otherwise cause the respec‐
cted agen
Prote AG.
tive line to break in the long-term.
– Ensure cleanliness at all times.

– 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 ➤
– When loosening the high pressure lines at the injectors with

an open-end spanner, use the injector connection piece -A- as
a counterhold. wage
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– Place removed parts on a clean, fluff-free surface ed and cover
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them. horis nte
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A clean plastic bag can also be used. ss c
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– Ensure that removed parts are not placed anywhere unpro‐
an
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– Use a vacuum-type cleaner to remove dirt from taper seat on
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high-pressure accumulator.
, is n
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hole
– Seal all connections with clean plugs from engine bung set -
spec
VAS 6122- .
es, in part or in w
t to the co
Installing
rrectness of i
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Note
nform
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♦ Making use of a setting tool to adjust the high pressure or in‐

jectors (piezo injectors) is not permissible.
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♦ Observe cylinder-specific markings if reusing high-pressure
n in
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♦ The high-pressure lines may be re-used after the following
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♦ If the taper seal of respective high-pressure line has been C py
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♦ The inside of the line must not be deformed, constricted or Prote
cted AG.
agen
damaged.
♦ Corroded lines should no longer be used.
– When new parts are to be installed, do not remove sealing

caps until installation work has begun.
– Install high pressure line with nothing else between high pres‐
sure pump and fuel rail.
– Install lines without tension.
Sequence
– Fit injection lines from fuel rail to injectors by hand first, tight‐
ening union nuts only hand tight to start with.
– If necessary, loosen bolts -arrows- in order to install lines with‐

out tension.
– Next install high-pressure line from high-pressure pump to
high-pressure accumulator.
– If necessary, loosen bolts of clamping pieces to ensure that
injectors can be rotated.
– Only tighten union nuts on high-pressure line from high-pres‐
sure pump to high-pressure accumulator by hand.

Caddy 2011 ➤
– First, tighten high-pressure line connections to injectors to

specified torque. When doing so, use an open-end spanner
on connecting piece -A- of injector as a counterhold.
– To tighten high-pressure lines, use torque wrench - V.A.G

1331- with ratchet - V.A.G 1331/1- and 17 mm socket -
T40055- .
AG. Volkswagen A
– Then, tighten high-pressure lines on fuel
kswrail to specified tor‐
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– Tighten the 4 high-pressure ulines
tho in the specified tightening or
sequence. ss a ac
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Note
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In order to position and tighten the union nut on the high-pressure
pump, the lifting eye must be movable. To ensure this, loosen the
rrectness of i
bolts -4-.
l purpos
– Tighten high-pressure line -2- between high-pressure pump

and fuel rail first at high-pressure pump -4- and then at fuel rail
nf
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Prote AG.

Caddy 2011 ➤
– Tighten nut -4- of high-pressure line with 17 mm socket - V.A.G

1331/6- .
– Tighten bolt -1- of the fuel high-pressure fuel line.
– To tighten high-pressure line, use torque wrench - V.A.G
1331- with ratchet - V.A.G 1331/1- and 17 mm socket -
T40055- .
– Tighten bolt -3- for high-pressure line bracket.
– Tighten fuel rail to specified torque.
– Bolt on lifting eye.
– 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 the fuel system with the ⇒ Vehicle diagnostic tester.
Note
After renewing the injectors, “perform adaptation of the correction

values” ⇒ Vehicle diagnostic tester. When doing athis,
gen Aselect
G. Volkswagen AG d
Reading / adapting correction values. Volksw
oes
not
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– Filling fuel system ⇒ page 277 . th
au
or
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– Check high pressure lines and connections for leaks. To do ce
e
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this, allow engine to run at idle for 5 minutes without pressing
du
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accelerator pedal.
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– Then, switch the engine off again.
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– Check the complete fuel system and return line connections

h re
hole
for leaks.
spec
es, in part or in w
– Wipe the connections with a clean cloth and check whether

t to the co
there is fuel on the cloth.

• Renew the affected component if leakage still occurs after
rrectness of i
tightening to the correct torque.

l purpos
• Tightening threaded connections further is not permissible.

– Then test drive the vehicle, accelerating to full throttle at least
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– Then check high-pressure section of fuel system again for

om
leakage.
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If there is still air in the fuel system, the engine can change to Cop py
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clear event memory ⇒ Vehicle diagnostic tester. Then continue co Vo
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Torque settings
♦ ⇒ “3.1 Assembly overview - fuel rail and injectors”, page 288

Caddy 2011 ➤
3.10 Removing and installing fuel rail

♦ Pliers - 3314-
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♦ Ratchet wrench - V.A.G 1331/1-

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Caddy 2011 ➤
♦ Socket - T40055-
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Special tools and workshop equipment required spec

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Removing
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WARNING
ss o
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inform

mer
atio

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– Detach electrical connector -arrow- from fuel pressure regu‐

r
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en
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lating valve - N276- .

t.
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Caddy 2011 ➤
– Disconnect electrical connector -B- on fuel pressure sender -

G247- .
– Pull vacuum hose -A- from cylinder head cover.
AG. Volkswagen AG d
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– Remove fuel return hose from fuel rail,
ris releasing hose clip
ed
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-arrow- to do so. ut
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– Open wiring harness retaining clips -arrows-.
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Caution
nform
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Make sure that no wiring connections are damaged when dis‐

m
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connecting the heater-element connectors.
com
tion in
r
Otherwise the whole wiring harness will need to be renewed.

te o
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Do not close the pliers - 3314- too firmly when pulling the glow
r
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plug connectors off as otherwise the support sleeve can be

fo
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damaged.
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– Position pliers - 3314- with groove -arrow A- on support sleeve
agen
Prote AG.
shoulder -arrow B- and pull plugs off glow pin plugs.

Caddy 2011 ➤
– Carefully pull connector off glow pin plug in

-direction of arrow-. agen
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spec
es, in part or in w
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– Unscrew bolt -2- and union nuts -1 and 3-, and remove high-
pressure line ⇒ page 304 .
rrectness of i
l purpos
nform
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tion in
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– Unscrew bolts -2-, lay coolant return line aside.
Co
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Prote AG.
– Unscrew bolts -arrows-, lay coolant return line aside.

– Detach line guide from fuel rail, and place it to one side.

Caddy 2011 ➤
– Remove high-pressure lines -1- ⇒ page 304 .

– Unscrew bolts -arrows- and remove fuel rail.
Installing
WARNING
For vehicles with solenoids, the learnt values from the fuel sys‐
tem must be reset following the renewal of the fuel pressure
regulating valve - N276- ⇒ Vehicle diagnostic tester.
– Install high-pressure lines (without tension). When doing so,

adhere to specified procedure and tightening sequence
⇒ page 304 .
Torque settings
3.11 Removing and installing injector seal in cylinder head cover

equipment required
♦ Assembly tool - T10208/2-
♦ Lambda probe open ring
spanner set - 3337-
♦ Tool set - T10055-
♦ Seal puller - T 40195-
♦ Torque wrench
(5 … 50 Nm) - V.A.G 1331-
AG. Volkswagen AG d
agen
♦ Tool set - T10133- Volksw
oes
not
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nl
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spec
es, in part or in w
t to the co
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313
cted agen
Prote AG.
3. Injectors/high-pressure accumulator (rail)
Caddy 2011 ➤
♦ Puller - T10402-
Removing
Note safety precautions ⇒ page 4 .
Observe rules for cleanliness ⇒ page 7 .
– Remove noise insulation at injectors.
– Remove only injectors (piezo injectors) whose injector seal is
to be renewed ⇒ page 298 .
– Move affected return lines slightly aside.
Caution
You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
Maintain cleanliness. No dirt must be allowed to get into the
disconnected fuel return lines or the open connections on the
injectors (piezo injectors).
First remove leaked oil or fuel with workshop equipment.
AG. Volkswagen AG d
– Position puller - T10055- together with injector extractor - wage
n oes
olks not
T10402- -1- and -2- as shown and pull injectors out upwards d by V gu
ara
by means of tapping movements. or
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h
ut ra
– Screw oil seal extractor - T40195- forcibly as far as possible
ss
a c
into seal by hand. ce
le
un
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rm
ab
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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
a
com
tion in
r
te o
thi
s
iva
do
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t.
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Cop py
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rig ht
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co Vo
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Rep. gr.23 - Mixture preparation - injection Prote AG.
Caddy 2011 ➤
Pull injector seal upwards by tapping gently using oil seal extrac‐
tor - T40195- , adapter - T101333/2- and slide hammer -
T10133/3- .
– After removal, check whether the spring washer is still on the
old seal.
If not, check that spring washer does not remain in injector shaft.
Installing
Caution
You must therefore proceed very carefully in order to avoid

unnecessary assembly work or further damage.
Remember that the cylinder head cover is made of plastic.
A plastic cylinder head cover is damaged easily during repairs.
Check cylinder head cover for damage.
– Initially position new injector seal by hand.

– Then carefully push new injector seal in as far as stop using
assembly tool - T10208/2- .
Torque settings
AG. Volkswagen AG d
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nl
pt
du
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ab
ility
ot p
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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
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nf
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n in
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sd
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AG. Volkswagen AG d
Caddy 2011 ➤ agen oes
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Vol
4-cylinder diesel engine (2.0 l engine, common rail) - Edition
ed
by 09.2016 gu
ara
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4 High-pressure pump
ce
le
un
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an
d
⇒ “4.1 Assembly overview - high-pressure pump”, page 316
itte
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ab
pe
⇒ “4.2 Removing and installing high-pressure pump”, page 317
ility
ot
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4.1 Assembly overview - high-pressure pump
h re
hole
spec
es, in part or in w
t to the co
1 - Ancillary bracket
⇒ page 56
rrectness of i
2 - Bolt
❑ Renew after removal l purpos
❑ 20 Nm +180°
nform
ercia
3 - Hub
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❑ Use counter-hold tool -
n in
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T10051- to loosen and

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tighten
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❑ To remove, use puller -
um
fo
T40064- .
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4 - High-pressure pump tooth‐ t. C rig
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5 - Bolts
agen
Prote AG.

❑ Qty. 3
❑ 20 Nm +45°
6 - Nut
❑ 95 Nm
7 - Bolt
❑ 20 Nm +45°
8 - High-pressure pump
❑ With fuel metering valve
- N290- (do not open)
❑ After renewing, initial
fuel filling must be car‐
ried out (never allow
pump to run dry)
⇒ page 277 .
9 - Fuel supply tank
10 - Fuel return hose
11 - High-pressure lines
❑ Between high-pressure pump and fuel rail
Note
♦ Observe cylinder-specific mark‐

lines.

Caddy 2011 ➤

checks:
tion and cracks.
aged.
be used.
❑ Install so that component is not under tension
❑ 28 Nm
AG. Volkswagen AG d
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4.2 Removing and installing high-pressure pump ol not
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Special tools and workshop ss
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equipment required
un
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ility
♦ Puller - T40064- with
ot
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T40064/1
, is n
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hole
♦ Torque wrench
spec
(5 … 50 Nm) - V.A.G 1331-
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
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t.
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Cop py
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rig ht
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Prote AG.
4. High-pressure pump 317

Caddy 2011 ➤
Removing
Caution
♦ Observe rules for cleanliness and the instructions for

working on the fuel system ⇒ page 7 .
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 277 .
♦ Protect open fuel connections from dirt entrainment using
suitable methods under all circumstances.
– Remove toothed belt from camshaft and high pressure pump

⇒ page 125 .
– Unscrew bolts -2-, remove toothed belt sprocket from high-
pressure pump.
Note
Disregard -item 1-. agen

AG. Volkswagen AG d
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ab
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ility
– Unscrew nut -1- on hub of high-pressure pump; counterhold
ot
with counter-hold tool - T10051- for this.
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
tio
– Position puller - T40064- with thrust piece - T40064/1- and pin

n in
r
- T40064/2- as shown and pull hub off high-pressure pump. If

te o
thi
necessary, use an open-ended spanner, width across flats 24

s
iva
do
mm, for counterholding.

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t.
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Prote AG.

Caddy 2011 ➤
– Unscrew bolts -2-, lay coolant return line aside.
Note
Disregard -items 1, 3-.
AG. Volkswagen AG d
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– Unscrew bolt -2- and union nuts -1, 3-; remove high-pressure
rm
ab
pe
line.
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, is n
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hole
spec
es, in part or in w
t to the co
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l purpos
nform
mercia
– Disconnect electrical connectors -1- and -3-. a

com
tion in
– Remove fuel supply hose -2- and return hose -4-.

r
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t.
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4. High-pressure pump 319

Caddy 2011 ➤
– Unscrew bolts -arrows- for high-pressure pump.

– Carefully remove high-pressure pump.
Installing
– Install toothed belt ⇒ page 125 .
– Install high-pressure lines ⇒ page 304 .
Caution
Risk of irreparable damage to high-pressure pump if allowed

to run dry. AG. Volkswagen AG d
agen oes
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♦ The high-pressure pump must first be filled with fuel before d byV
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the engine is started. The high-pressure pump mustornot ise nte
be allowed to run while still empty. Initial fuel filling h eo
aut ra
⇒ page 277 . ss c
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un
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an
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– Read out event memory and, if necessary, delete the event
erm
ab
memory entry.
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Torque settings
h re
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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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c
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or
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Cop py
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Prote AG.

Caddy 2011 ➤
5 Intake manifold
⇒ “5.1 Assembly overview - intake manifold”, page 321
⇒ “5.2 Removing and installing intake manifold”, page 322
⇒ “5.3 Removing and installing throttle valve module J338 ”, page
325
5.1 Assembly overview - intake manifold
1 - Guide tube
❑ For oil dipstick.
2 - Sealing ring agen
AG. Volkswagen AG d
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❑ Renew afterby V removal
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3 - Seal uthor tee
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❑ Renew
ss after removal
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4 - Bolt
an
d
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❑ 8 Nm
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6 - Coolant line
hole
7 - Bolt spec
es, in part or in w
t to the co
❑ 9 Nm
8 - Bolt
rrectness of i
❑ 9 Nm
l purpos
9 - Intake manifold
nform
ercia
⇒ page 322
m
10 - Bolt
com
tion in
❑ 9 Nm
r
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11 - Bracket
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❑ For exhaust gas recircu‐

fo
en
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lation cooler change‐

n
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over valve - N345- .
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12 - Bolt
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❑ 9 Nm
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Prote AG.

cooler changeover valve -
N345-
14 - Seal
15 - Connecting pipe
❑ To exhaust gas recirculation cooler.
16 - Bolt
❑ 20 Nm
17 - Clamp
❑ 5 Nm
18 - Connection
❑ For exhaust gas recirculation
5. Intake manifold 321

Caddy 2011 ➤
19 - Bolt
❑ 8 Nm lkswage es n
o ot g
byV ua
20 - Sealing ring ir se
d ran
tee
ho
❑ Renew after au removal
t or
ac
ss
21 - Throttle valve control module - J338- with throttle valve potentiometer - G69-
ce
e
nl
pt
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22 - Bolt
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❑ 8 Nm
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hole
23 - Bolt
spec
es, in part or in w
❑ 9 Nm
t to the co
24 - Clip
rrectness of i
l purpos
5.2 Removing and installing intake manifold

nf
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or
♦ Pliers - 3314-
m
m
atio
om
n in
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thi
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sd
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♦ Socket T 30 - T10405-

AG. Volkswagen AG d
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d b ara
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autho
4-cylinder diesel engine (2.0 l engine, e o common
ra rail) - Edition 09.2016
ss c
ce
e
Removing
nl
pt
du
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itte
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WARNING
ility
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spec
es, in part or in w
t to the co
rrectness of i
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Notes on hose connections with screw-type clamps ⇒ page 241
nf
ercia
o
– Remove air intake hose. To do this, loosen hose clip -2-.
rm
m
atio
om
n in
or c
Note
thi
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Disregard -item 1-.
o
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by
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Prote AG.

– Loosen hose clip -2- on throttle valve module - J338- with
throttle valve potentiometer - G69- . Pull air pipe off but leave
in installation position.
– Disconnect electrical connectors at glow plugs ⇒ page 374 .
– 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.

olkswagen AG
wag en AG. V
Caddy 2011 ➤ olks
does
not
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se dcommon rail) - Edition 09.2016
b ara
n ri tee
ho
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– Unscrew bolts -2-, lay coolant returnssline aside.
a ac
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ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

– Unscrew union nuts of relevant high-pressure line -1 to 4- and
nform
ercia
remove corresponding high-pressure line. Ensure cleanliness

m
a
and adhere to prescribed procedure ⇒ page 304 .
com
tion in
r
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thi
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cum
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en
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t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
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Prote AG.

– Unscrew union nuts -1- and -3- and remove high-pressure line.
Ensure cleanliness and adhere to prescribed procedure
⇒ page 304 .
– Disconnect wiring connector -2- at throttle valve module -

J338- with throttle valve potentiometer - G69- .
– Remove bolt -1- for dipstick guide tube.
Note

Caddy 2011 ➤
– Open and remove clip -1-.
Note
Disregard -item 2-. agen

AG. Volkswagen AG d
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– Unscrew bolts -arrows- for intake manifold diagonally from
wit
, is n
outside to inside using socket T30 - T10405- .
h re
hole
spec
– Carefully remove intake manifold.
es, in part or in w
t to the co
Installing
rrectness of i
l purpos
Note
nform
ercia
Renew seals.
m
at
om
i
– Tighten intake manifold bolts from inside out in diagonal se‐
on
c
quence.
in t
or
his
ate
– Install air pipe. do

priv
cum
or
– Install high-pressure lines. Ensure cleanliness and adhere to

f
en
ng
t.
yi
prescribed procedure ⇒ page 304 .
Co
Cop py
ht. rig
– Install fuel rail ⇒ page 309 . rig ht
py by
co Vo
by lksw
– Install noise insulation, if removed ⇒ General body repairs, cted agen
Prote AG.
Torque settings
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 321
5.3 Removing and installing throttle valve

module - J338-

Caddy 2011 ➤
Removing
Volkswagen AG
terior; Rep. gr. 66 ; Noise insulationsw.agen AG. does
k not
Vol gu
Notes on hose connections with by
dscrew-type clamps ⇒ page 241 ara
se ri nte
ho eo
– Loosen hose clamps -1-
au and -2- and remove air hose.
t ra
c
ss
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un
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d
itte
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rm
ab
pe
ility
ot
wit
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spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
ercia

m
a
com
tio
n in
r
te o
thi
s
iva
do
- G31- and remove air pipe.
r
rp
cum
fo
en
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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.
– Disconnect electrical connector -2-.

– Remove bolt -1- for dipstick guide tube.
– Unscrew bolts -arrows- and remove throttle valve module -
J338- with throttle valve potentiometer - G69- .
Installing
Note
Renew O-ring.
Torque settings
♦ ⇒ “5.1 Assembly overview - intake manifold”, page 321

Caddy 2011 ➤
6 Senders and sensors AG. Volkswagen AG d

agen oes
ksw
⇒ “6.1 Removing and installing exhaust gas pressure sensorby
Vol 1 not
gu
ara
G450 ”, page 327 rised
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⇒ “6.2 Removing and installing air mass meterssG70 ”, page 328
a ra
c
ce
le
⇒ “6.3 Checking fuel pressure regulating valve N276 ”,
un
pt
an
page 329
d
itte
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rm
ab
⇒ “6.4 Removing and installing fuel pressure regulating valve
pe
ility
N276 ”, page 330
ot
wit
, is n
h re
⇒ “6.5 Removing and installing fuel pressure sender G247 ”, page
hole
spec
334 es, in part or in w
t to the co
6.1 Removing and installing exhaust gas
pressure sensor 1 - G450-
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
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iva
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cum
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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by c lksw
cted agen
Prote AG.
The exhaust gas pressure sensor 1 - G450- determines the load‐

ing of the particulate filter.
Removing
– Before removing, spray solvent on hoses of exhaust gas pres‐
sure sensor 1 - G450- .
6. Senders and sensors 327

Caddy 2011 ➤
– Disconnect electrical connector -2- from exhaust gas pressure

sensor 1 - G450- .
olkswagen AG
en AG. V
– Carefully pull the hoses off the connecting piecesolkinswa
agstraight does
not
line. The two connections can easily break offed
bthe exhaust gas
y V gu
ara
pressure sensor 1 - G450- . ho
ris nte
eo
t
au ra
– Unscrew bolt -3- from exhaust gas pressure
ss sensor 1 - G450- c
bracket.
ce
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nl
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Installing itte
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ab
ility
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wit
, is n
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hole
Note
spec
es, in part or in w
t to the co
♦ 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‐
rrectness of i
sation).
l purpos
♦ Make sure that hoses are securely fitted and seal properly.
♦ If the pressure line on the particulate filter was loosened, tight‐
nform
ercia
en pressure line.
m
at
♦ Carry out adaptation after renewing exhaust gas pressure
om
ion
sensor 1 - G450- and/or particulate filter ⇒ Vehicle diagnostic
c
in t
or
tester.
his
ate
do
priv
cum
or
Torque settings
f
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ng
t.
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♦ ⇒ “2.1 Assembly overview - particulate filter”, page 351 Cop py
t. rig
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yri
♦ ⇒ “3.1 Assembly overview - exhaust gas temperature regula‐ p by
o Vo
by c lksw
tion”, page 363 Prote
cted AG.
agen
6.2 Removing and installing air mass meter

- G70-
Removing

Caddy 2011 ➤

– Carefully pull air mass meter - G70- out of guide on air filter
housing.
Installing
To ensure the proper function of the air mass meter - G70- it is
important to adhere to the following work sequences.
Note
♦ If the air filter element is very dirty or wet, particles of dirt or

water may reach the air mass meter and falsify the measured
air mass value. This would lead to loss of power, since a
smaller injection quantity is calculated.
♦ Always use Genuine part for air filter element.
♦ Always renew seal if damaged (infiltrating air).
♦ Use a silicone-free lubricant to install the air hose and seal.
– Check for salt residue, dirt and leaves in air mass meter and
air hose (clean air side).
wage es n
– Check intake duct for contamination up to air filter element.Vol
ks If ot g
by ua
contamination is found, remove salt residues, dirt edand leaves ran
ris
from top and bottom part of air filter housingubytho rinsing out or
tee
or
using a vacuum cleaner if necessary. ss
a ac
ce
e

nl
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itte
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Torque settings
erm
ab
ility
ot p
wit
, is n
h re
hole
6.3 Checking fuel pressure regulating valve

spec
es, in part or in w
- N276- t to the co

rrectness of i

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted
♦ Measuring container, fuel-resistant
agen
Prote AG.

Caddy 2011 ➤
WARNING
♦ Read the rules for cleanliness for all work on the fuel sys‐
tem ⇒ page 7 .
• Engine at operating temperature.

• Air conditioner switched off
Procedure
– Detach fuel return hose from fuel rail. To do this, release hose
clip -arrow-.
– Seal open fuel return hose using a bung from engine bung set
- VAS 6122- .
lkswage es n
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rm
ab
pe
ility
– Connect auxiliary hose -2- to return connection of high pres‐

ot
wit
, is n
sure accumulator -3-.

h re
hole
– Hold auxiliary hose in measuring container -4- to measure re‐

spec
turn quantity.
es, in part or in w
t to the co
– Start engine and run at idling speed for 30 seconds.

• Specified amount in 30 seconds: 90 to 110 ml
rrectness of i
If the specification is not attained, the fuel pressure regulating

l purpos
valve - N276- is defective.

If the engine cannot be started, carry out check at starter speed.
nform
ercia
• Specification: return volume 0 ml

m
a
com
tio
If the specification is not attained, the fuel pressure regulating

n in
r
te o
valve - N276- is defective.

thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
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pyri by
Vo
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6.4 Removing and installing fuel pressure
c by lksw
cted agen
Prote AG.
regulating valve - N276-

AG. Volkswagen AG d
agen oes
olksw not
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ed b Caddy
ara
nte
2011 ➤
ris
4-cylinder diesel
th engine (2.0 l engine, common rail) - Edition
o e o09.2016
au ra
c
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
l purpos
♦ Open jaw socket insert AF 30 - V.A.G 1332/15-
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Caddy 2011 ➤
Fuel pressure regulating valve - N276- -arrow- is located in the

fuel rail. It maintains constant pressure in the fuel rail 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 agen

AG. Volkswagen AG d
oes
working on the fuel system ⇒ page 7 . y Volksw not
gu
d b ara
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♦ Always follow these rules for cleanliness and instructionshoris nte
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s aut ra
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s
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un
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d

itte
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erm
ab
– Before removal, clean the area of the thread around the fuel
ility
ot p
pressure regulating valve - N276- with brake cleaner. Under
wit
is n
no circumstances may dirt enter the hole of the fuel rail.
h re
ole,
spec
t to the co
Note
♦ Fuel pressure regulating valve - N276- must be renewed each
rrectne
time after removing.
♦ Do not allow any cleaning agent to get into the connector,
ss
clean it carefully.
o
cial p
f inform
mer
– Dry fuel pressure regulating valve - N276- .
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 ➤
– When loosening union nuts -2-, use hexagonal part -3- of

housing to counterhold. Then unscrew fuel pressure regulat‐
ing valve - N276- by hand.
– Extract dirt from hole of high pressure accumulator (threads
and sealing surface). Do not use tools or other instruments for
this purpose.
– Seal hole of fuel rail using a plug from engine bung set - VAS
6122- .
Installing
WARNING
For vehicles with solenoids, the learnt values from the fuel sys‐
tem must be reset following the renewal of the fuel pressure
regulating valve - N276- ⇒ Vehicle diagnostic tester.
Note
♦ The fuel pressure regulating valve - N276- has a deformable

sealing lip and no separate seal; it can therefore be used only
once.
♦ Make sure that sealing surfaces (deformable sealing lip) and
threads on new fuel pressure regulating valve - N276- are un‐
damaged.
♦ Check sealing surface in hole of fuel rail.
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
ulating valve - N276- must be moistened with diesel.
Volkswa AG. gen AG
agen does
olksw not
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db ara
– Renew oil seal -1-. rise nte
tho eo
– Tighten union nut -2- by hand. au ra
c
ss
ce
e
– Align new fuel pressure regulating valve so that connecting

nl
pt
du
an
line is free of tension after connector is attached.

itte
y li
erm
ab
– Counterhold in this position at connection -3- of regulating

ility
ot p
valve using an open-end spanner or pliers.

wit
, is n
h re
– Use open jaw socket insert AF 30 - V.A.G 1332/15- to tighten

hole
spec
union nut -2-.

es, in part or in w
t to the co
– Install fuel rail ⇒ page 309 .

– After mounting, leave engine running at moderate speed for a
few minutes and then switch off again.
rrectness of i

l purpos
– Read event memory.

nform
ercia
– Then road test the vehicle, accelerating to full throttle at least

once. Then, check high-pressure system again for leaks.
m
at
om
ion
c

in t
or
his
ate
Torque settings
do
priv
cum
or

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 ➤
6.5 Removing and installing fuel pressure

sender - G247-
. Volkswagen AG
gen AG does
Special tools and workshop equipment
Vol
ksw
a required not
y gu
db ara
♦ Torque wrench (40 ...
or
is200
e Nm) - V.A.G 1332- nte
th eo
s au ra
c
s
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
♦ The fuel pressure sender - G247- -2- is located in the fuel rail.
It measures the current fuel pressure in the high-pressure sys‐
tem and transmits a voltage signal to the engine control unit -
J623- .
Removing
Caution
Read through the rules for cleanliness and the instructions for
working on the fuel system ⇒ page 7 .
Follow these instructions before starting work and while work‐
ing on the fuel system.
– Clean threaded area around the regulating valve with, for ex‐
ample, commercially available degreaser before removing it.
Under no circumstances may dirt enter the hole of the fuel rail.

Caddy 2011 ➤
Note
Do not allow any cleaning agent to get into the connector, clean
it carefully.
– Dry fuel pressure sender - G247- .
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
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nl
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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 ➤
– Release connector -1- from fuel pressure sender - G247- -2-

and pull off.
– Unscrew fuel pressure sender - G247- -2-. agen
AG. Volkswagen AG d
oes
olksw not
V gu
– Use suction device to extract dirt from high-pressure accumu‐ ed by ara
nte
lator bore (threads and sealing surface). Do not use any tho ris
eo
mechanical tools to do this. s au ra
c
s
ce
le
– Seal hole of fuel rail using a plug from engine bung set - VAS
un
pt
6122- .
an
d
itte
y li
erm
ab
ility
ot p
Note
wit
is n
h re
ole,
spec
Seal off drilling immediately with a suitable plug to prevent dirt
from entering.
t to the co
Installing
rrectne
ss o
Note
cial p
f inform
mer
♦ Fuel pressure sender - G247- has a deformable sealing lip,
atio
m
not a seal, for sealing purposes.

o
n
c
i
or
n
♦ Check that sealing surfaces (deformable sealing lip) and
thi
te
sd
a
threads on fuel pressure sender - G247- are undamaged. Re‐

iv
o
pr
c
using fuel pressure sender - G247- if possible if it has been
um
r
fo
tested OK.
en
ng
t.
yi Co
op py
♦ Also check sealing surface in hole of high pressure accumu‐ t. C rig
gh ht
lator. yri
p by
o Vo
by c lksw
cted
♦ Start of thread and deformable sealing lip of fuel pressure reg‐
agen
Prote AG.
ulating valve - N276- must be moistened with diesel.
– Tighten fuel pressure sender - G247- by hand.

– Tighten fuel pressure sender - G247- to specified torque.
Note
The high-pressure connections must “not” be opened for bleed‐

ing; fuel system bleeds itself automatically.
– Filling fuel system ⇒ page 277 .

– 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
AG. Volkswagen AG d
agen oes
o lksw not
yV gu
If there is still
ise d air
b in the fuel system, the engine can
ara change to
n
emergency hor running mode during road test. Switch offteengine
eo and
ut
clearsevent
s a memory. Then continue with a road test. r ac
ce
e
nl
pt
du
an
itte
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erm
ab
Torque settings
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 ➤
7 Lambda probe
⇒ “7.1 Removing and installing Lambda probe G39 ”, page 338
7.1 Removing and installing Lambda probe

- G39-
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
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cu
o
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f
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ng
t.
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Removing Cop py
t. rig
gh ht
yri
– Disconnect electrical connector -arrow- for Lambda probe - p by
co Vo
G39- .
by lksw
cted agen
Prote AG.

Caddy 2011 ➤
– Unscrew Lambda probe - G39- -3-, using tool from Lambda

probe open ring spanner set - 3337- .
Installing
Note
♦ Threads of new Lambda probes are already coated with as‐

sembly paste; the paste must not get into the slots on the probe
body.
♦ In the case of a used lambda probe, grease only the thread
with high-temperature paste ⇒ Electronic Parts Catalogue
(ETKA) . The high-temperature paste must not get into the
slots on the probe body.
♦ When installing, the Lambda probe's aelectrical
gen AG
. Volkwiring
swagenconnec‐
AG d
tion must always be re-attachedVoin lksthe
w same locations to oes n
ot
prevent the Lambda probe cable d by
from coming into contact with guaran
ir se
the exhaust pipe. tho
tee
o
au ra
c
ss
Torque settings
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
tion”, page 363
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.
7. Lambda probe 339

Caddy 2011 ➤
8 Air filter
⇒ “8.1 Assembly overview - air filter housing”, page 340
⇒ “8.2 Removing and installing air filter housing”, page 341
8.1 Assembly overview - air filter housing
1 - Intake hose
❑ To turbocharger.
❑ Check for soiling and
leaves.
2 - Air mass meter - G70-
⇒ page 328
3 - O-ring
4 - Vacuum hose
❑ To charge pressure
control solenoid valve -
N75- .
❑ Vacuum hose connec‐
tion diagram
⇒ page 279
5 - Bolt
❑ 2 Nm
AG. Volkswagen AG d
agen
6 - Air filter upper part Volksw
oes
not
gu
by ara
❑ Remove dirt, leaves and rise
d
nte
salt residues utho eo
ra
s a c
s
7 - Intake air guide
ce
le
un
pt
❑ Bolted to lock carrier.
an
d
itte
y li
❑ Remove dirt, leaves and
erm
ab
salt residues
ility
ot p
wit
is n
8 - Bolt
h re
ole,
❑ 2 Nm
spec
t to the co
9 - Air intake hose
❑ Remove dirt, leaves and
salt residues rrectne
10 - Water drainage pipe

s
11 - Air filter lower part

s o
cial p
❑ Remove dirt, leaves and salt residues

inform
mer
❑ Clean connection for drainage pipe

atio
m
❑ For cold countries, an air filter lower part is installed with a hose for hot air intake.
o
n
c
i
or
❑ Country-specific version: With snow screen.

thi
te
sd
va
12 - Bolt
i
o
pr
cum
r
fo
❑ 8 Nm
en
ng
t.
yi Co
op
13 - Air filter element
C py
t. rig
gh ht
yri
❑ Observe change intervals ⇒ Maintenance ; Booklet 39
p by
co Vo
by lksw
cted agen
14 - Bolt
Prote AG.
❑ 2 Nm

Caddy 2011 ➤
15 - Connecting pipe
❑ From cylinder head cover
❑ For crankcase breather system
AG. Volkswagen AG d
agen oes
lksw not
8.2 Removing and installing air filter hous‐ Vo gu
d by ara
ise nte
ing or eo
h
aut ra
ss c
Removing
ce
le
un
pt
an
d
– Release retaining clips on sides -arrows- and pull off air ductitte
y li
cover.
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
ercia
m
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
– Press in locking lugs -1- and -3- and pull connecting hose -4-
off air filter housing -2-. If lugs are too rigid, remove air filter
housing together with connecting hose. When removing air
filter housing together with connecting hose, make sure to
carefully lift both components out, turning them slightly while
doing so.
8. Air filter 341

Caddy 2011 ➤
– Detach electrical connector -1- from air mass meter - G70- and
pull off hose -2-.
– Unscrew bolt -3- and remove air filter housing.
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
– Remove water drain hose -arrow- from lower part of air filter.
y li
rm
ab
Remove dirt and leaves from the connection and the hose.
pe
ility
ot
wit
, is n
h re
hole
Note
spec
es, in part or in w
t to the co
As it is difficult to gain access to clip on suction hose, it is better
to remove intake connecting pipe from turbocharger.
rrectness of i
l purpos
nform
ercia
– Remove crankcase breather hose -1-.

m
a
com
tion in
– Pull off vacuum hoses -arrows- from suction hose -3- and
r
te o
make accessible. Unclip bracket.
thi
s
iva
do
– Completely unscrew bolt -2- (make sure bolt is captive).
r
rp
cum
fo
en
g
– Swing intake union to the right and remove with suction hose
n
t.
yi Co
op
-3-. C py
t. rig
gh ht
yri by
Installing cop Vo
by lksw
cted agen
Prote
AG.

Note
♦ Use a silicone-free lubricant to install the air hose.
Torque settings

Caddy 2011 ➤
9 Engine (motor) control unit

⇒ “9.1 Removing and installing engine (motor) control unit J623
”, page 343
⇒ “9.2 Removing and installing anti-theft engine control unit J623
”, page 344
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
Volkswagen AG
– Remove plenum chamber bulkhead ⇒ General body repairs; agen
AG. does
ksw
Rep. gr. 50 ; Body - front, plenum chamber bulkhead
by .
Vol not
gu
ara
d
ise nte
– Completely unscrew bolts -arrows- of controlthunit
or cover. eo
au ra
c
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Undo nuts -arrows- of control unit bracket.
l purpos
– Release connector from engine control unit and pull off.
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
– Press catches -1- and -2- outwards. Then pull engine control
AG.
unit off control unit bracket in -direction of arrow-.

Installing
– Push engine control unit onto control unit bracket until it en‐
gages in catches.
– Connect connectors and lock.
9. Engine (motor) control unit 343

Caddy 2011 ➤
– Tighten nut -arrows-.

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
– Tighten bolts -arrows-.
– Check previous coding and adapt new control unit ⇒ Vehicle
rrectne
diagnostic tester.
– Read event memory of new engine control unit and clear if
ss
necessary ⇒ Vehicle diagnostic tester.
o
cial p
f in
– Install plenum chamber bulkhead ⇒ General body repairs;
form
mer
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
atio
om
– Carry out road test.
n
c
i
or
n thi
e
– Again read control unit event memory.

t
sd
iva
o
pr
c
Specified torque
um
r
fo
en
ng
t.
yi Co
Component Specified torque t. Cop py
rig
gh ht
Securing nuts for control unit 10 Nm pyri by
Vo
co lksw
by
Securing bolts for control unit 5 Nm
cted agen
Prote AG.
9.2 Removing and installing anti-theft en‐

gine control unit - J623-
Removing
If the engine control unit is to be replaced, connect ⇒ Vehicle di‐
agnostic tester and carry out Renew control unit .
– Remove wiper arms ⇒ Electrical system; Rep. gr. 92 ; Wind‐
screen wiper system; Removing and installing wiper arms .
Rep. gr. 50 ; Body - front, plenum chamber bulkhead .
– Push retaining frame down in -direction of arrow- and remove

Caddy 2011 ➤
– Unscrew shear-head bolts -arrows- using a pair of pliers.
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
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
– Insert screwdriver between both locking plates -arrow-.
t to the co
– Carefully press screwdriver in -direction of arrow- and bend
retaining bar -1- upwards at the same time.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
– Bend retaining bar -1- in direction of -arrow- until it can be

um
r
fo
en
ng
pulled off connectors.

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Push locking devices of connectors in -direction of arrow- and

pull off connectors.
Installing
9. Engine (motor) control unit 345

Caddy 2011 ➤
– Fit connectors to engine control unit and slide locking devices

onto stop in -direction of arrow-.
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
– Fit retaining bar -1- onto connectors and press it in direction
rm
ab
pe
of -arrow-.
ility
ot
wit
, is n
– Insert pin -2- as far as stop into hole on valve timing housing.
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
– Use new shear-head bolts to secure retaining bar onto engine
a
com
tio
control unit -arrows-.
n in
r
te o
thi
– Evenly tighten shear-head bolts -arrows- until bolt heads
s
iva
do
shear off.
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.
– Place engine control unit into retaining frame and push it up‐
wards in -direction of arrow-.
– Install plenum chamber bulkhead ⇒ General body repairs;
Rep. gr. 50 ; Body - front; Plenum chamber bulkhead .
– Wiper arms ⇒ Electrical system; Rep. gr. 92 ; Windscreen
wiper system; Removing and installing wiper arms .

Caddy 2011 ➤
26 – Exhaust system
1 Exhaust pipes, silencers
⇒ “1.1 Assembly overview - silencers”, page 347
⇒ “1.2 Cutting exhaust pipe”, page 348
⇒ “1.3 Aligning exhaust system free of stress”, page 349
⇒ “1.4 Installation position of clamp”, page 350
1.1 Assembly overview - silencers

AG. Volkswagen AG d
agen oes
olksw not
Note d by V gu
ara
rise nte
tho eo
♦ After working on the exhaust system, ensure that
s a the system
u ra
c
is not under stress and that there is sufficient clearance to the s
ce
e
bodywork. If necessary, loosen double clamp and align si‐
nl
pt
du
an
lencer and exhaust pipe so that sufficient clearance is main‐
itte
y li
tained to the bodywork and the support rings are evenly
erm
ab
ility
loaded.
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
1 - Clamping sleeve
❑ Before tightening, align
cold exhaust system
rrectness of i
free of tension
l purpos
❑ Tighten bolted connec‐

tions evenly.
nf
ercia
❑ Fitting position
orm
⇒ page 350
m
atio
m
❑ 25 Nm
o
n in
or c
thi
e
2 - Front silencer
t
sd
iva
o
r
rp
cu
3 - Retaining ring for front si‐
o
m
f
lencer en
ng
t.
yi Co
op
❑ Renew if damaged C py
t. rig
gh ht
yri by
4 - Bracket cop Vo
by lksw
cted agen
❑ Observe installation po‐ Prote AG.
sition
5 - Bolt
❑ 25 Nm
6 - Mounting
❑ With retaining ring
7 - Rear silencer
8 - Separation 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 347

Caddy 2011 ➤
❑ The connection is made with a clamp.
❑ Evenly tighten threaded connections of clamping sleeve
❑ Installation position of rear clamp ⇒ page 350
❑ Cutting exhaust pipe ⇒ page 348 .
9 - Bracket
❑ Observe installation position
10 - Retaining ring for rear silencer
11 - Tunnel cross-piece
1.2 Cutting exhaust pipe

♦ Chain-type pipe cutter - VAS 6254-
♦ or body saw - VAS 6780-

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
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.
348 Rep. gr.26 - Exhaust system

AG. Volkswagen AG d
Caddy 2011 ➤
gen engine
4-cylinderolkdiesel (2.0 l engine,
oes common rail) - Edition 09.2016
swa no
yV t gu
db ara
Procedure ir se nte
ho eo
aut ra
– Cut through exhaust at separating point pipessat right 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
nform
mercia
at
om
ion
c
in t
or
his
e
1.3 Aligning exhaust system free of stress

at
do
priv
cum
or
Procedure
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.
1. Exhaust pipes, silencers 349

Caddy 2011 ➤
4-cylinder diesel engine (2.0 l engine, common rail) - Edition AG. Volkswagen AG d
gen 09.2016
swa oes
k not
Vol gu
d by ara
1.4 Installation position of clamp
e nte
ris
utho eo
ra
a c
ss
ce
le
un
pt
Note
an
d
itte
y li
rm
ab
Gradual introduction of clamp with continuous clip.
pe
ility
ot
wit
, is n
h re
Specified torque and mounting dimensions of clamping sleeve.
hole
spec
Clamp -A- with 2 individual clips.
es, in part or in w
t to the co
Specified torque: 25 Nm
Clamp -B- with continuous clip.
rrectness of i
Specified torque: 35 Nm
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
c
Installation position of clamp
um
fo
en
ng
t.
yi
– Install clamp so that end of bolt -arrow- does not extend be‐
Co
Cop py
yond lower edge of clamp.
t. rig
gh ht
pyri by
Vo
o
• The threaded connection of the front clamp faces to the right.
c by lksw
cted agen
Prote AG.
• The threaded connection of the rear clamp faces to the rear.

Caddy 2011 ➤
2 Exhaust gas cleaning

⇒ “2.1 Assembly overview - particulate filter”, page 351
⇒ “2.2 Assembly overview - catalytic converter”, page 353 lkswage es n
o ot g
byV ua
d
⇒ “2.3 Removing and installing particulate filter”, page o354ir se
ran
tee
th or
u
2.1 Assembly overview - particulate filter
a ac
ss
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
wit
♦ Removing and installing exhaust manifold ⇒ page 253 .
, is n
h re
♦ After working on the exhaust system, ensure that the system hole
spec
es, in part or in w
t to the co
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
rrectness of i
loaded.
l purpos
♦ If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is renewed, then the sensor must, without exception,
be adapted ⇒ Vehicle diagnostic tester.
nf
ercia
or
m
m
atio
m
♦ The flexible joint of the front exhaust pipe must be secured

o
n in
or c
with transportation lock - T10404- to stop overstretching.
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.
2. Exhaust gas cleaning 351

Caddy 2011 ➤
1 - Exhaust gas pressure sen‐ agen

AG. Volkswagen AG d
oes
sor 1 - G450- Volksw not
gu
by ara
❑ Removing and rise installing
d
nte
⇒ page 327
autho eo
ra
ss c
2 - Connector
ce
e
nl
pt
du
an
3 - Nut
itte
y li
erm
ab
❑ 10 Nm
ility
ot p
wit
4 - Shield
, is n
h re
hole
5 - Lambda probe - G39- with
spec
Lambda probe heater - Z19-
es, in part or in w
t to the co
❑ Grease only thread of
sender using high-tem‐
perature paste ⇒ Elec‐
rrectness of i
tronic Parts Catalogue
(ETKA) .
l purpos
❑ The high-temperature
paste ⇒ Electronic parts
nform
ercia
catalogue (ETKA) must

not get into the slots on
m
at
om
the probe body.
ion
c
in t
r
❑ 52 Nm
o
his
ate
❑ Removing and installing do

priv
⇒ page 338
um
for
en
ng
t.
yi
6 - Exhaust gas temperature
Co
op py
sender 4 - G648- t. C rig
gh ht
yri by
❑ 60 Nm cop Vo
by lksw
cted agen
Prote
7 - Seal
AG.

sition
8 - Clamp
❑ 7 Nm
❑ 60 Nm
10 - Bolt
❑ 25 Nm
11 - Mounting
12 - particulate filter
❑ With oxidation catalytic converter and front exhaust pipe.
❑ After renewing particulate filter, adaptation of ash mass comparison must be set to “0” ⇒ Vehicle diag‐
nostic tester.
13 - Nut
❑ 25 Nm
14 - Bracket
❑ Replacing particulate filter bracket with riveted stud bolt ⇒ Electronic Parts Catalogue .
❑ This is the only way to apply the necessary specified torque.
15 - Bracket
❑ Bolted to diesel particulate filter

Caddy 2011 ➤
16 - Bracket
❑ Bolted to cylinder head. agen
AG. Volkswagen AG d
oes
olksw not
17 - Bolt ed byV gu
ara
is nte
❑ 25 Nm ut
hor eo
a ra
s c
18 - Bolt s
ce
le
un
pt
❑ 3 Nm
an
d
itte
y li
19 - Bolt
rm
ab
pe
ility
❑ 3 Nm
ot
wit
, is n
h re
20 - Nut hole
spec
❑ 8 Nm
es, in part or in w
t to the co
21 - Clamp
rrectness of i
l purpos
2.2 Assembly overview - catalytic converter
nform
mercia
Note
a
com
tion in
r
♦ After working on the exhaust system, ensure that the system

te o
thi
s
iva
do
r
bodywork.
rp
cum
fo
en
ng
♦ If necessary, loosen double and single clamps and align si‐

t.
yi Co
op
lencers and exhaust pipe so that sufficient clearance is main‐
C py
ht. rig
tained to the bodywork and the support rings are evenly loaded rig ht
py by
⇒ page 349 .
co Vo
by lksw
cted agen
Prote AG.
♦ Removing and installing exhaust manifold with turbocharger
⇒ page 253 .
♦ The flexible joint in the front exhaust pipe must not be bent
more than 10° since otherwise it can be damaged.
♦ Renew seals, gaskets and self-locking nuts.
Note
♦ 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 352)

♦ Exhaust gas temperature sender 3 - G495-
⇒ Item 9 (page 352)
♦ Exhaust gas temperature sender 4 - G648-
⇒ Item 6 (page 352)
♦ Lambda probe - G39- ⇒ Item 5 (page 352)
♦ Bracket ⇒ Item 14 (page 352)

Caddy 2011 ➤
1 - Catalytic converter
2 - Seal
sition
3 - Clamp
❑ 7 Nm
4 - Mounting
5 - Nut
❑ 25 Nm
AG. Volkswagen AG d
agen oes
6 - Bracket Volksw not
gu
by ara
❑ Particulate filter bracket rised
nte
with riveted studs ⇒ aut
ho eo
ra
Electronic Parts Cata‐ ss c
logue .
ce
le
un
pt
an
d
❑ This is the only way to

itte
y li
apply the necessary
rm
ab
pe
specified torque.
ility
ot
wit
, is n
7 - Nut
h re
hole
❑ 25 Nm
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
The flexible joint in the front exhaust pipe must not be bent more
t.
yi Co
op
than 10° since otherwise it can be damaged. C py
t. rig
gh ht
yri by
If the catalytic converter is to be re-installed, a transportation lock
op Vo
by c lksw
- T10404- -arrow- must always be secured to the flexible joint in cted agen
Prote AG.
front exhaust pipe.
2.3 Removing and installing particulate filter


Caddy 2011 ➤
♦ Engine support - 3300 A-
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
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Bracket - T10346-
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 ➤
♦ Ring ratchet spanner, 13 mm AF - T10384-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
♦ Transport lock - T10404-

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.
♦ Flange bolt M6x20

Removing
– Remove Lambda probe ⇒ page 338 .
– Disconnect connector -3- for Lambda probe - G39- and con‐
nector -2- for exhaust gas temperature sender 1 - G235- .

Caddy 2011 ➤

separate.
on turbocharger.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
le

un
pt
bocharger.
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
– Only loosen bolt -1-.
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.
– Disconnect electrical connector -2- on exhaust gas pressure

sensor 1 - G450- .
– Unscrew bolts -3- and -4-.

Caddy 2011 ➤
– Unclip exhaust gas pressure sensor 1 - G450- lines with brack‐

et -1- from upper toothed belt guard.
– Place exhaust gas pressure sensor 1 - G450- on particulate
filter.
– Remove exhaust temperature sender 3 - G495- with spanner
- T10395/6- ⇒ page 365 .
Vehicles with all-wheel drive:
– Remove propshaft ⇒ Propshaft and rear final drive; Rep. gr.
39 ; Final drive, differential; Rear final drive .
– Remove right drive shaft ⇒ Running gear, axles, steering;
Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft . . Volkswagen AG d
gen AG wa oes
olks not
– Remove subframe ⇒ Running gear, axles, steering; by
V Rep. gr. gu
ara
ed
40 ; Subframe; Removing and installing subframe
or
is . nte
eo
th
au ra
Vehicles with front-wheel drive: ss c
ce
le
un
– Lower subframe ⇒ Running gear, axles, steering; Rep. gr.
pt
an
d
40 ; Subframe; Lowering subframe from model year 2011 .

itte
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ility
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– Unscrew exhaust gas temperature sender 4 - G648- -item 1-
ole,
spec
from exhaust pipe downstream of particulate filter.
t to the co
Note
rrectne
Disregard -item 2-.
ss o
cial p
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mer
atio
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– Unscrew bolts -arrows- and remove heat shield for right drive
iv
o
r
shaft.
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Prote AG.

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

wrench - T10384- .
– Unscrew nuts -2-.
– Remove particulate filter bracket.
Replacing particulate filter bracket with riveted stud bolt ⇒ ETKA
(Electronic Parts Catalogue) .
– Unscrew bolts -2- and -3- of pendulum support.
Caution
Risk of damage to damper element.

♦ The decoupling element must be secured with transpor‐
tation lock - T10404- .
AG. Volkswagen AG d
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– Loosen nuts -1- and push clip forwards -arrow-. s
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– Unscrew nuts and remove rear tunnel cross-piece -3-.

nf
ercia
– Only unscrew front mounting on rear part of exhaust system

orm
-1-.
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Prote AG.

Caddy 2011 ➤
– Remove nuts -arrows- of heat shield.

– Unscrew and remove clamping washers -2- and -3-.
lkswage es n
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– Unscrew bolts -arrows-. ir se
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Caution
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• Do not mount bracing device - 3300 A- on or against sump.
y li
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t to the co
rrectness of i
– Bolt bracket - T10346- on securely with bolt -2-.
l purpos
2 - Flange bolt M6x20

– Secure engine support - 3300 A- to bracket - T10346- .
nform
ercia
– Position bracing device - 3300 A- against lower edge of crank‐

m
at
case.
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– Force engine forwards with spindle of engine support - 3300

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A- .
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Note
Co
Cop py
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Observe connecting lines, hoses and radiator when moving en‐ cop Vo
by lksw
gine/gearbox assembly. cted agen
Prote AG.

Caddy 2011 ➤
– Note the following in particular:

• Do not allow the air conditioning compressor -2- to touch the
refrigerant line -1- -arrow-.
• The alternator must not contact the refrigerant line.
• The pressure pipe must not contact the radiator.
AG. Volkswagen AG d
agen oes
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– Remove particulate filter by turning it 180° around its own axis. s
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es, in part or in w
t to the co
rrectness of i
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– If the particulate filter is to be re-installed, a transportation lock

nform
- T10404- -arrow- must always be secured to the flexible joint

ercia
in front exhaust pipe.

m
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Installing
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Note
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♦ Renew seals, self-locking nuts and clip for particulate filter.
rig ht
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♦ Attach cable ties in all the same places when installing.
cted agen
Prote AG.
♦ Replacing particulate filter bracket with riveted stud bolt ⇒

ETKA (Electronic Parts Catalogue) .
♦ This is the only way to apply the necessary specified torque.

Caddy 2011 ➤
Observe sequence when installing particulate filter:
1 Position particulate filter on turbo charger and loosely attach clip -1-
2 Screw bolts and nuts -2…5- in by hand
• It must still be possible to move particulate filter and bracket
3 Tighten clip -1-

4 Tighten nuts and bolts -2- and -5-
5 Tighten nuts and bolts -3- and -4-
– Make sure that the cables are in the correct position. They are
held in position together on the heat
swa
shield
gen AG by clip -A-.
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– Install noise insulation under
se
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y ara
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– Install pendulum support
au ⇒ page 32 .
th ra
ss c
– Installing exhaust temperature sender 4 - G648-
ce
le
un
pt
⇒ page 363 .
an
d
itte
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erm
– Align exhaust system free of stress ⇒ page 349 .

ab
ility
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– Install lambda probe - G39- and exhaust gas pressure sensor

wit
is n
1 - G450- ⇒ page 338 .

h re
ole,
spec
If the particulate filter or the exhaust gas pressure sensor 1 -

G450- is renewed, then the sensor must, without exception, be

t to the co
adapted ⇒ Vehicle diagnostic tester.

Torque settings
rrectne

ss

o
cial p
tion”, page 363

inform
mer
♦ Subframe; Assembly overview - subframe ⇒ Rep. gr. 40 ;

atio
Assembly overview - subframe

om
n
c
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or
♦ Drive shafts; Assembly overview - drive shafts ⇒ Rep. gr. 40 ;

thi
te
Assembly overview - drive shaft

sd
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♦ Propshaft; Assembly overview - propshaft ⇒ Rep. gr. 39 ;

fo
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Assembly overview - propshaft

t.
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Cop py
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Vo
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Prote AG.

Caddy 2011 ➤
3 Exhaust gas temperature regulation

⇒ “3.1 Assembly overview - exhaust gas temperature regulation”,
page 363
⇒ “3.2 Removing and installing exhaust gas temperature sender
1 G235 ”, page 364
3 G495 ”, page 365
4 G648 ”, page 367
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.
1 - Exhaust turbocharger
⇒ page 253
2 - particulate filter
AG. Volkswagen AG d
❑ Removing and installing olksw
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not
⇒ page 354 d byV gu
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3 - Nut ut
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❑ 9 Nm ss
ce
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un
pt
4 - Bracket
an
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itte
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❑ Bolted to diesel particu‐
erm
ab
late filter
ility
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5 - Hose
h re
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spec
6 - Bracket
t to the co
7 - Exhaust gas pressure sen‐

sor 1 - G450-
rrectne
⇒ page 327
8 - Bracket
ss o
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9 - Bolt
inform
mer
❑ 4.5 Nm
atio
m
10 - Bolt
o
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or
❑ 8 Nm
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11 - Exhaust gas temperature

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❑ Thread of sender is . Cop py
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grease. Prote AG.
❑ 60 Nm
3. Exhaust gas temperature regulation 363

Caddy 2011 ➤
⇒ page 365
12 - Lambda probe - G39-
❑ Grease only thread with high-temperature paste . The high-temperature paste ⇒ Electronic Parts Cata‐
logue (ETKA) must not get into the slots on the probe body.
❑ 52 Nm
❑ Thread of sender is coated.
❑ Do not additionally oil or grease.
❑ 60 Nm lkswage es n
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❑ Removing and installing ⇒ page 367 ir se
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14 - Exhaust gas temperature senderau 1 - G235- ac
ss
❑ 60 Nm
ce
le
un
pt
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itte
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ab
ility
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temperature sender 1 - G235-
spec
t to the co
rrectness o
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Cop py
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♦ Tool insert, AF 17 mm - T10395- p by
co Vo
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Prote AG.

Caddy 2011 ➤
Removing n AG. Volkswagen AG do

wage e
– Disconnect connector for exhaust o temperature sender 1 - s not g
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gas
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G235- -2-. ris
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– If fitted, remove noise insulation
ss
a ⇒ General body repairs, ex‐ ac
ce
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nl
pt
du
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itte
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ility
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spec
es, in part or in w
t to the co
– Unscrew exhaust temperature sender 1 - G235- -1- and re‐
rrectness of i
move from exhaust manifold from below.
l purpos
Note
nform
mercia
at
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ion
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Installing
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ate
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– Attach cable ties in all the same places when installing.

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Cop py
Installation position of exhaust gas temperature sender - G235- .
t. rig
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• Angled shaft must have a distance -a- = 3 … 5 mm to bolting Prote AG.
of turbocharger support.
Torque settings
tion”, page 363
♦
♦


Caddy 2011 ➤
Caution
Thread of exhaust gas temperaturelksender 3 - G495- is coated.

Do NOT additionally greasewa gen with
AG. Vohigh temperature
swagen AG
does paste and
always adhere byto Vol the prescribed tightening
ks not
gu torque
⇒ page 363 . Otherwise,
ris
ed the threaded connection can abecomeran
tee
loose and subsequent
utho failures can then occur. or
a ac
ss
ce
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nl
pt
du
Removing
an
itte
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erm
ab
– Disconnect electrical connector -1- for exhaust temperature

ility
ot p
sender 3 - G495- and free electrical line.

wit
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hole
on turbocharger.
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
– Unscrew exhaust gas temperature sender 3 - G495- opposite

om
io
-direction of arrow-.
n
c
in t
or
his
e
Installing
at
do
priv
cum
or

f
en
ng
t.
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– Attach cable ties in all the same places when installing. t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Caddy 2011 ➤
olkswagen AG
wa en AG. V rail)
gcommon - Edition
does 09.2016
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Installation position of exhaust temperature sender 3 - G495-
ris
e
tee
-item 1-: tho or
au ac
ss
• Angled end facing left side of vehicle.
ce
le
un
pt
an
d
• Angle -α- to mark -arrow- = approx. 17°.
itte
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rm
ab
pe
ility
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
– Screw exhaust temperature sender 3 - G495- in by hand.
l purpos
– Then apply tightening torque using torque wrench - V.A.G
1331- together with wrench from tool set - T10395/6- .
nform
ercia
– Install Lambda probe - G39- ⇒ page 338 .

m
a
com
tio
Torque settings
n in
r
te o
thi
s
iva
do
tion”, page 363
r
rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


Caddy 2011 ➤
Caution
Thread of exhaust gas temperature sender 4 - G648- is coated.

Do NOT additionally grease with high temperature paste and
always adhere to the prescribed tightening torque
⇒ page 363 . Otherwise, the threaded connection can become
loose and subsequent failures can then occur.
Removing
separate.
on turbocharger.
– Unscrew exhaust gas temperature sender 4 - G648- -item 1-

from exhaust pipe downstream of particulate filter.
Note
Disregard -item 2-.
Installing agen
AG. Volkswagen AG d
oes
olksw not
V
Install in reverse order of removal, observing the following: ed by gu
ara
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Torque settings aut
h
ra
ss c
ce
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nl
pt
tion”, page 363
du
an
itte
y li
erm
ab
ility
ot p
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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
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d Caddy 2011 ➤
agen
Vo4-cylinder
lksw diesel engine o(2.0
es n l engine, common
ot g rail) - Edition 09.2016
d by ua
ran
e
oris tee
th
4 Exhaust gas recirculation u or
a ac
ss
ce
le
un
⇒ “4.1 Assembly overview - exhaust gas recirculation”,
pt
an
d
page 369 itte
y li
erm
ab
⇒ “4.2 Removing and installing exhaust gas recirculation cooler”,
ility
ot p
page 370
wit
is n
h re
ole,
⇒ “4.3 Checking changeover for exhaust gas recirculation cooler”,
spec
page 372
t to the co
⇒ “4.4 Checking exhaust gas recirculation cooler for leaks”, page
373
rrectne
4.1 Assembly overview - exhaust gas recirculation
ss o
1 - Bolt
cial p
f inform
❑ 9 Nm
mer
atio
m

o
n
c
pipe
i
or
n thi
e

t
sd
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pr
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of cracking
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t.
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op
3 - Bolt C py
t. rig
gh ht
❑ 9 Nm yri
p by
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by c lksw
cted
4 - Seal
agen
Prote AG.

5 - Vacuum line
❑ Do not alter shape.
❑ Vacuum hose schemat‐
ic diagram ⇒ page 279
6 - Bolt
❑ 9 Nm
7 - Seal
pipe
of cracking
9 - Bolt
❑ 9 Nm
10 - Clamp
❑ 5 Nm
cooler
❑ With integrated exhaust gas recirculation valve 1 - GX5-
❑ Checking changeover ⇒ page 372 .
12 - Bolt
❑ 9 Nm
13 - Seal
4. Exhaust gas recirculation 369

Caddy 2011 ➤
14 - Seal
15 - Exhaust gas recirculation pipe
❑ With flexible joint; do not bend flexible joint - risk of cracking
16 - Nut
❑ 22 Nm
17 - Bolt
❑ 9 Nm
18 - Seal
4.2 Removing and installing exhaust gas re‐

circulation cooler olkswage es n
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by ara
Special tools and workshop equipment
ris required
ed nte
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♦ Hose clamps, up to 25 mm au
-ss3094- ra
c
ce
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d
itte
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rm
ab
pe
ility
ot
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos

nform
mercia
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com
tion in
r
te o
thi
s
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do
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t.
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Cop py
t. rig
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Vo
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by
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Prote AG.

agen
AG. Volkswagen AG d
oes Caddy 2011 ➤
ksw
4-cylinder diesel enginey Vol (2.0 l engine, common rail)
not
-gEdition
ua 09.2016
db ran
rise te
♦ Hose clip pliers - VAS 6362- tho eo
s au ra
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s
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nl
pt
du
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itte
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ab
ility
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es, in part or in w
t to the co
rrectness of i
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Removing
nform
ercia
– Remove particulate filter ⇒ page 354 .

m
at
om
io
n
c
in t
or
case.
his
ate
do
riv
– Open clip -3- and pull intake hose off air mass meter - G70- .
p
cum
for
en
g

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t.
yi Co
Cop py
– Unscrew bolt -2-, swing intake hose with suction pipe to rear,
t. rig
gh ht
yri
and pull it off turbocharger.
p by
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by c lksw
cted agen
Prote AG.
– Loosen hose clip -1- and remove pulsation damper -2-.


Caddy 2011 ➤
– Unscrew bolts and remove pipes -A- for exhaust gas recircu‐
lation.
– Remove right flange shaft ⇒ Power transmission; Rep. gr.
39 ; All-wheel drive - renewing flange shaft seals; Renewing
right flange shaft seal .
Continued for all vehicles olkswage es n
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byV ua
– Remove oil lines onriturbocharger
se
d and turbocharger support rante
⇒ page 198 . tho eo
au ra
c
ss
ce
le
un
gine.
pt
an
d
itte
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erm
ab
– Clamp off coolant hoses -1- and -3- with hose clamps to 25 mm
ility
ot p
- 3094- , loosen hose clips and remove hoses from exhaust
wit
is n
gas recirculation cooler.
h re
ole,
spec
t to the co
– Remove vacuum hose -4- from vacuum unit and free.
– Unscrew bolts -arrows- and remove exhaust gas recirculation
cooler.
rrectne
Installing
ss
o
cial p
f inform
mer
atio
Note
om
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i
or
n thi
♦ Renew gaskets, seals and self-locking nuts.

te
sd
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ng
t.
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op
C py
t. rig
gh
ht
pyri by
Vo
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by
cted agen
Prote
– Fit heat shield sleeve in the same place when installing.
AG.
– Installing support for turbocharger with oil supply line, inlet

connection and pulsation damper ⇒ page 249 .

On all-wheel drive vehicles, install right flange shaft ⇒ Running
gear, axles, steering; Rep. gr. 39 ; All-wheel drive - renewing
flange shaft seals; Renewing seal for right flange shaft .
– Checking engine oil level ⇒ page 172 .
– Check coolant level ⇒ page 207 .
Torque settings
♦ ⇒ “4.1 Assembly overview - exhaust gas recirculation”,
page 369
4.3 Checking changeover for exhaust gas

recirculation cooler

Caddy 2011 ➤
Procedure
– Raise vehicle.
– Pull off heat protection -2- from vacuum servo element.
– Pull off vacuum hose -1- from vacuum servo element and con‐
nect hand vacuum pump - VAS 6213- in its place. gen AG
. Volkswagen AG
d a oes
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Vol gu
d by ara
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ris
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an
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itte
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erm
ab
ility
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wit
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h re
ole,
spec
– Operate hand vacuum pump to create a vacuum.
t to the co
• The linkage of the changeover for the exhaust gas recircula‐
tion cooler must move -arrows-.
If linkage does not move or only moves in jerks:
rrectne
♦ Vacuum actuator is defective.
ss
♦ Changeover flap for exhaust gas recirculation is tight.
o
cial p
f inform
– Fit heat shield sleeve in the same place when installing.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
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pr
4.4 Checking exhaust gas recirculation

um
r
fo
en
ng
t.
cooler for leaks
yi Co
Cop py
t. rig
gh ht
Special tools and workshop equipment required yri
p by
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by c lksw
cted
agen
Prote AG.
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 .

Caddy 2011 ➤
28 – Glow plug system

1 Glow plug system
⇒ “1.1 Removing and installing glow plug”, page 374
⇒ “1.2 Removing and installing automatic glow period control unit
J179 ”, page 376
. Volkswage
⇒ “1.3 Removing and installing engine gen AG sender G28
aspeed ”,opage
n AG d
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lksw
376 by Vo ot g
ua d ran
ise
ut
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Hall sender G40 ”, page 378 tee
or
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1.1 Removing and installing glow plug
ce
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nl
pt
du
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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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nf
ercia
orm
m
atio
om
n in
♦ 10 mm jointed spanner - 3220-

or c
thi
te
sd
iva
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cu
o
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f
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
♦ Pliers - 3314-
Removing
374 Rep. gr.28 - Glow plug system

Caddy 2011 ➤
AG. Volkswagen AG d
agen 4-cylinder diesel
oes engine (2.0 l engine, common rail) - Edition 09.2016
olksw not
V gu
by ara
ed
– Cleanhglowris pin plug opening in cylinder head. It must nte
e o be en‐
t o
sured
s au that no dirt falls into the cylinder when this is beingr a done.
c
s
ce
le
un
pt
an
d
Note
itte
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rm
ab
pe
ility
♦ Cleaning procedure:
ot
wit
, is n
h re
♦ Use a vacuum cleaner to remove coarse dirt.
hole
spec
♦ Spray brake cleaner or suitable cleaning agent into glow plug
es, in part or in w
t to the co
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.
rrectness of i
l purpos
– Open retaining clips -arrows- of wiring harness and disconnect

electrical connectors from glow plugs.
nform
ercia
Caution
m
a
com
tion in
♦ Make sure that no wiring connections are damaged when
r
te o
thi
disconnecting the glow pin plug connectors. Otherwise the
s
iva
do
whole wiring harness will need to be renewed.
r
rp
cum
fo
en
g
♦ Do not close the pliers - 3314- too firmly when pulling the
n
t.
yi Co
glow pin plug connectors off as otherwise the support
Cop py
t.
sleeve can be damaged.
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Position pliers - 3314- with groove -arrow A- on support sleeve

shoulder -arrow B- and pull plugs off glow pin plugs.
– Carefully pull connector off glow pin plug in

-direction of arrow-.
– Clean glow pin plug opening in cylinder head. It must be en‐
sured that no dirt falls into the cylinder.
1. Glow plug system 375

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– Open cable guide fasteners to free wiring harness.
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Removing and installing battery tray .
– Pull out relay carrier -2- in -direction of arrow- from underneath
electronics box in engine compartment.
– Remove automatic glow period control unit - J179- -1-.
Installing
Install in reverse order of removal.
1.3 Removing and installing engine speed

sender - G28-

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Installing
Torque settings
♦ ⇒ “2.1 Assembly overview - cylinder block, gearbox end”, page
73

Caddy 2011 ➤
1.4 Removing and installing Hall sender -

G40-
Removing
– Remove toothed belt from idler pulley and high-pressure pump
⇒ page 125 .
Note
♦ The toothed belt need not be removed completely.

♦ Cover ⇒ Item 28 (page 124) does not need to be removed.
– Disconnect connector -arrow- for Hall sender - G40- , and pull

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– 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 plugs as
specified in ⇒ ETKA (Electronic Parts Catalogue) .
– Fit toothed belt and adjust the valve timing ⇒ page 125 .
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D3E802F2683-4-Cylinder Diesel Engine (2 0 L Engine Common Rail)

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D3E802F2683-4-Cylinder Diesel Engine (2 0 L Engine Common Rail)

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Copyright © 2016 Volkswagen AG, Wolfsburg D3E802F2683

1.4 Securing engine on engine and gearbox support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.5 Installing engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.1 Assembly overview - assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2.2 Adjusting assembly mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2.3 Removing and installing motor mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.1 Removing and installing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1 Cylinder block (pulley end) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.1 Assembly overview - crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.2 Assembly overview - ancillary bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1.3 Assembly overview - sealing flange, belt pulley end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.5 Checking radial clearance of conrods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

15 - Cylinder head, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.3 Measuring radial clearance of camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3.4 Removing and installing camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

3.5 Removing and installing camshaft oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.6 Checking hydraulic compensation elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

4 Inlet and exhaust valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

4.3 Checking valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

4.4 Valve dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Sump, oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.1 Assembly overview - sump/oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

1.2 Removing and installing oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

1.3 Removing and installing oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

1.5 Engine oil: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

1.1 Coolant hose schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

1.3 Draining and adding coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

2.2 Removing and installing coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

3.1 Assembly overview - radiator/radiator fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

23 - Mixture preparation - injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267

2.1 Connection diagram - vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

3.3 Testing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

3.7 Checking low pressure fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

3.8 Removing and installing injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298

4.2 Removing and installing high-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

5.1 Assembly overview - intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

6 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

6.2 Removing and installing air mass meter G70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

7 Lambda probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338

26 - Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347

28 - Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

1 Glow plug system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

(VRL009251; Edition 09.2016)

1.1 Engine number/engine data

stamped on the engine as previously. The fourth digit shows the

can be found on the joint between engine and gearbox.

code” and “serial number”.

The engine number consists of up to 9 characters (alphanumeric).

The first part (maximum 4 characters) makes up the “engine

code”, and the second part (6 characters), the “serial number”. If

Manufactured 08.10 08.10 04.10 08.10

Identification code CLCB CLCA

Identification code CLCB CLCA

2 Rep. gr.00 - Technical data

2.1 Safety regulations for working on fuel

♦ Ensure sufficient clearance to all moving or hot compo‐

very hot (danger of scalding)!

♦ Wear eye and hand protection when performing any type

When removing and installing fuel gauge sender or fuel pump

♦ Place the suction hose of an activated exhaust gas extraction

system close to the assembly opening of the fuel tank to ex‐