Repair manual car Volkswagen Caddy (2003-2008). | Catalog-cars

Repair manual car Volkswagen Caddy (2003-2008).

25 Feb 2015 | Author: | Comments Off on Repair manual car Volkswagen Caddy (2003-2008).

Repair manual car Volkswagen Caddy (2003-2008).

Volkswagen Caddy 2003-2008-manual repair, maintenance and operation of the vehicle.

In this book, based on original information considered model year 2003.

This guide contains general information about the structure of the various modifications of the car, maintenance tips, descriptions of all engine systems, steering with hydraulic or electric actuators, brake systems with ABS and ESP provides detailed information on the operation of power systems and engine management, including pump-injectors for diesel engines, replacing a high pressure fuel pump.

Also shows the geometrical dimensions, fabrication body elements and electrical diagrams of all vehicle systems that contain enough information to diagnose and repair.

Description:

In this book, based on original information considered model year 2003. Guide describes the gasoline engines:

1.4 l (BCA and BUD (55 kW));

1.6 l (BGU, BSE and the BSF (75 kW));

as well as diesel engines:

1.9 l TDI (BSU (55 kW), BJB, BLS (77 kW) turbocharged and with pump-injectors);

This guide contains general information about the structure of the various modifications of the car, maintenance tips, descriptions of all engine systems, steering with hydraulic or electric actuators, brake systems with ABS and ESP provides detailed information on the operation of power systems and engine management, including pump-injectors for diesel engines, replacing a high pressure fuel pump. Also shows the geometrical dimensions, fabrication body elements and electrical diagrams of all vehicle systems that contain enough information to diagnose and repair.

The book includes the following chapters:

– Instruction manual;

1.4 l (BCA and BUD (55 kW));

1.6 l (BGU, BSE and the BSF (75 kW));

as well as diesel engines:

1.9 l TDI (BSU (55 kW), BJB, BLS (77 kW)

2.0 l SDI (BDJ, BST (51 kW)

Car maintenance:

Vehicle maintenance and repair-complex control actions carried out at regular intervals over the life of the vehicle and intended to maintain the health of the car and the timely detection of hidden defects. Maintenance consists of inspection, which conducted a Visual inspection and inspection devices all units and vehicle systems, and maintenance, which makes replacement of materials and parts, and other maintenance work. List of checks and scheduled maintenance is optimized and compiled through analysis of operational properties of a car that is held continuously by the company-manufacturer.

The frequency is determined by the end of the so-called conditions, for which a different periodicity. These conditions are the basic conditions that depend on original equipment car. Deviation from the prescribed environmental conditions alters the conditions for the reduced service schedule service schedule mileage or time interval.

-To identify the conditions of the test vehicle’s code, specified on the label with the data of car: QG0 QG1 or OG2. PR number sets the mežservisnye intervals.

-To see the sticker with the car, open the lid (1) on the left side of the front of the cabin.

-Vehicle data label above the fuse compartment. Car symbol with the following code bundling rules mean QG1 LongLife service. QG2 or QG0 means mežservisnye-defined intervals depending on mileage or time without increasing mileage, unlike rules LongLife.

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Content:

Indicator lamps in the instrument cluster 10

The frequency of the 33

Identification of the modalities of the 33

34 inspection

Preparatory work prior to the 34

Lift the car on the lift platform and the Jack 34

Visual inspection of the BATTERY 34

Check BATTERY electrolyte level and 35

Check the BATTERY voltage with no load 35

Tyres: check the condition of the paintings wear, tread height pressure 36

Checking the brake fluid level inspection in the 36

Visual inspection of the brake system for leaks and damage to 36

Check lining thickness of brake pads front and rear disc brakes 37

Visual inspection of the anther joints of equal angular velocity (w ENG) 37

Check couplings for lateral steering Rod fastening, clearance and tightness of the anther 37

Checking the oil level in the tank power steering 37

Visual inspection the hinges axle 38

Visual inspection of the engine and engine compartment parts (top and bottom) for leaks and damage 38

Check the engine oil level 38

Checking the status of antifreeze and coolant level cooling system 38

Poliklinovoj strap: 39 status test

Check the positioning of the electric window regulator 39

Run the test drive 40

Removing and replacing the BATTERY 41

Replacement of brake fluid 42

Change engine oil and filter 43

Replacing the oil filter 43

Removing and installing engine top jacket 44

Replacing the fuel filter in a diesel engine 45

Replacement filter element

air filter-46.

Checking camshaft timing belt drive (4-cyl petrol engines) 47

Checking camshaft timing belt drive (only SDI engines and TOÏ) 47

Timing belt replacement timing 48

Replacement timing remiâ timing petrol engines and 1.4 l 8SA BUD 48

Timing belt replacement timing in 1.6 litre petrol engines with BGU marks ALL BCF 51

Timing belt replacement timing in diesel engines TDI and SDI 53

Removal, installation and tensioning the timing belt for a car made before 05.2005 (building set near the engine) 53

Timing belt removal and installation (in vehicles with the engine set well away from the engine) 56

Replacing spark plugs 59

Change oil and filter in a b-stulennatoj GEARBOX with double clutch 02Ê 60

Replacement filter 60

Changing oil 60

Install the oil level 61

Check headlight adjustment 61

2. GASOLINE ENGINES 63

Technical characteristics. -. 63

1.4 l petrol engines 64

Removing and replacing parts lubrication system 83

Parts and components of the hydraulic part of the cooling system 87

Removing and installing the cooling system components 92

Elements of the cooling system on a 92

Parts and components of the cooling system,

installed on the engine 93

Removing and replacing the radiator fan (V7) and the radiator Fan 2 (V177) 94

Removing and installing the heat sink 94

Removing and replacing the coolant pump 94

General information about removal and installation elements system 95

Assembly and disassembly of the fuel tank 95

Disconnect the fuel supply system with collision 96

Disassembly and Assembly of the fuel manifold with injectors 96

Air filter housing for engines of the GSA 97-letter

Air filter housing with BUD-Letter 97

Control unit cleaning throttle body

Removing and installing fuel injectors 98

Exhaust system 100

Details and components, engine code GSA 100

Details and components, engine code BUD 101

1.6 l petrol engines (BSE, BGU and BSF) 102

Removing the 1.6 l petrol engine (with letter symbols, BSE and BGU 8SF) 103

Assembly and disassembly of the 1.6 l petrol engine (BGU, BSEn BSF) 105

Parts and components of 105

Removing the top timing belt cover 106

Removing and installing the poly-v belt 106

Transfer belt without air conditioner compressor 107

Belt drive air compressor with 107

The cylinder block 107

Cover and flywheel 107

Removing and replacing the rear cover of the cylinder block 107

Replacing the front lid of the cylinder block 108

Crankshaft 108

Šatunno-piston unit 110

Parts and components of piston group šatunno-110

Check the cylinders, pistons and piston rings 111

Check the thermal gap piston rings 111

Check the clearance between the ring kanavka and 111

Check the cylinder diameter of 111

Size pistons and cylinders 111

The head of the cylinder block 111

Parts and components of cylinder heads 111

Check availability for CENTRAL crease 112

Removing and replacing the CENTRAL 112

Removal, installation and toothed belt tension 113

The valve mechanism 115

Oil filter with heat exchanger 120

Removing and replacing the oil pan 120

Removing and replacing the oil pump 121

Cooling system 121

Parts and components of the cooling systems s installed on 121 engine

Removing and replacing the coolant pump 123

Air supply system and fuel injection 123

Technical Hara kteristiki 123

Specification of parts and units of air supply, BGU, daigatelej BSE BSF 124

Parts and components of the fuel manifold with injectors for engines 1.4 l GSA 8UD and 1.6 litre, BGU.BSE.BSF 126

Parts and components of the system of filing and 127 air filtration

Removing and installing lower intake manifold engines BGU 127

Removing and installing lower intake manifold engines BSE BSF, 128

Removal and installation of 128 nozzles

Exhaust system 129

Parts and components of the receiver with the catalyst 130

Parts and components of secondary and main silencer 130

EGR system on vehicles with engines of BGU 131

Secondary air system, engines, BGU BSE 131

Technical data 1.9 litre diesel engines with alphabetic symbols BJB, BSU, BLS 133

Technical characteristics of diesel engine 2.0 l with alphabetic symbols 8DJ, BST 133

134 engine repair

Drive support mechanisms of 134

The cylinder block and its 135 sites

Removing and installing the poly-v belt 135

Belt drive air compressor without 136

Belt drive air compressor with 136

Removal and installation of the cylinder end cover and flywheel 136

Crankshaft bearings and 139

Šatunno-piston group 140

Check the thermal gap piston rings 141

Check the clearance between the ring kanavka and 141

Check the cylinder diameter 141

Fitting position of pistons and cylinders 142

Measurement of piston protrusion of the cylinder at TDC position 142

Marking gaskets cylinder head 142

Size pistons and cylinders of 142

Parts and components of the cooling system, mounted on the back of 153

Parts and components of the cooling system on the engine 154

Removing and installing the fuel level sensor 171

Removal and installation of the dual pump 171

Air supply system 173

Air supply system with Turbo diesel engine 1.9 l

BJB 173 Letter

Air supply system with Turbo diesel 1.9 l-letter BLS and BSU 176

Removing and installing turbocharger 178

Air supply system without turbocharger 179

Fuel injection system 180

Specification of pump-injectors for diesel engines with 1.9 l SJB.BLS.BSU, and 2.0 l diesel engines VKS, BDJ, BST 180

Parts and components of the exhaust system catalyst engines with alphabetic abbreviations: 182, BSU BJ8

Parts and components of the exhaust system catalyst engines-letter; BLS 183

Parts and components of the system vypusha with a particulate filter. Engine code BLS 183

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