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Subject: Repair manual car Volkswagen Caddy (2003-2008).


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    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);
    2.0 l SDI (BDJ, BST (51 kW) without turbo-pump with nozzle),
    with mechanical transmission boxes.
    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;
    -Maintenance;
    -Petrol engines;
    -Diesel engines;
    – Transmission, including two sections that describe the ILAC and one section – drive shafts;
    -Wheel Suspension;
    -Steering;
    – Braking systems;
    -A c a detailed description of the inspection dimensions required for maintenance work and for mounting artwork elements which are;
    -The electrical connections and a full list of the items of electrical equipment.
    [collapse]


    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)
    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.
    [collapse]


    Content:

    INSTRUCTIONS for USE 9
    An overview 9
    Driver: 9
    Combination unit 9
    Indicator lamps in the instrument cluster 10
    -Multifunction display in the instrument cluster 11
    The mileage counters, average speed and fuel consumption 12
    Ambient temperature indicator 12
    Indicator lights 12
    Multifunctional display menu 12
    Set of keys to the vehicle 14
    Central locking switch 15
    Remote central lock 15
    Device protecting from opening sliding door 15 children
    16 lighting
    Instrument illumination and lighting switch 16
    Tilt-beam headlights 16
    Control wipers 16
    Exterior rear-view mirror 17
    Seat heating 17
    Signs and mailbox for dressings 17
    The Office heating cabin 17
    Driving 18
    Steering wheel adjustment (if any) 16
    18 safety
    Traction control system (ASR) 19
    Castle-ignition switch and devices with an antitheft device 19
    Fuse 19
    Fuses (SC) in the block under the left front panel 19
    Fuses (SB) located in the switching unit in the engine compartment on the left 21
    Location relay fuse, since May 24, 2005
    Fuses (SA) block on the BATTERY 24
    Fuses (SB) located in the switching unit in the engine compartment, on the left 24
    Fuses (SC) in a block with the left front panel 26
    Filament lamp 30
    Technical specifications 31
    1. MAINTENANCE of 33
    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
    Of the 41
    Removing and replacing the BATTERY 41
    Cars with petrol engines 41
    Cars with diesel engines 41
    42 wheel bolts
    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 installing engine 1.4 l (GSA and BUD) 64
    Assembly and disassembly of the engine (GSA and BUD) 65
    Belt drives 66
    Removing and installing the poly-v belt 66
    Block cylinders 1.4 l petrol engines (GSA and BUD) 66
    Removing and replacing the front and rear crankshaft covers 68
    Removing and replacing the rear cover of the cylinder block 69
    Disassembly and Assembly of the piston and connecting rod 72
    Check the thermal gap at joints of piston rings 73
    Check Pistons 73
    Check the cylinder diameter 73
    Cylinder head 73
    Removing and replacing the cylinder head 73
    Assembly and disassembly of the cylinder goloaki 75
    Removing and replacing the camshaft housing 79
    Repair of the valve mechanism 80
    Lubrication system 83
    Lubrication system 83
    Removing and replacing parts lubrication system 83
    Ohlaždenij system 86
    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
    Fuel system 95
    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 {Word J338) 98
    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
    Parts and components of the valve mechanism 115
    Contact CENTRE-plane 116 processing
    Valve size 116
    Valve seat machining 116
    Intake valve seat machining 116
    The exhalation valve seat machining 117
    Check the Guide bushings valves 117
    Removing and replacing the camshaft 117
    Camshaft, check the axial run 118
    Lubrication 118
    Oil pump 119
    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
    3. DIESEL ENGINES 133
    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 engine cylinder head 142
    Check availability for hogging 146 GBCna
    Removing and replacing the lid CENTRAL 146
    Removing and replacing the cylinder head 146
    Repair of the valve mechanism 148
    Camshaft, valves and pump/nozzle drive 148
    Verification of the axial camshaft off run 150
    Dimensions 150 valves
    Removing and replacing the camshaft 150
    151 smaèki system
    Oil return pipe pressure turbocharger bearings 153
    Cooling system 153
    Parts and components of the cooling system, mounted on the back of 153
    Parts and components of the cooling system on the engine 154
    Wiring diagram cooling system hoses 155
    Specification of the elements of the cooling system 156
    Fuel system fuel injection and 170
    Fuel supply system 170
    Parts and components of fuel filter 170
    Fuel radiator 171
    Removing and installing the fuel delivery unit 171
    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
    Wiring diagram of vacuum hoses 181
    Accelerator pedal 182
    Exhaust system 182
    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
    EGR 185
    Muffler bracket 186
    4. TRANSMISSION 189
    189 General information
    Clutch 190
    Repair mechanism clutch 190
    Gear 191
    Gear box 191
    Removal of 191
    Install PPC 192 0AN
    Assembly and disassembly of the PPC 194 0AN
    Removing and replacing the cover of Carter gearbox and gears 5th gear 195
    Removing and replacing the crankcase KP 196
    Removal and installation of the secondary shaft, shaft, differential gear, gear, gear mechanism and forks including 196
    Internal gear shift MANUAL TRANSMISSION type AAPO 198
    Assembly and disassembly of the internal mechanism of the transmission 199
    Primary and secondary shafts 200
    Removing and installing the shaft 200
    Removal and installation of the secondary shaft 203
    Assembly and disassembly of the secondary shaft 205
    Differential 207
    Disassembly and Assembly of the differential gear 208
    Manual 5-speed gearbox type 209 0A4
    Technical characteristics of 209
    CAT enclosure type 210 0A4
    Gear 211
    Removing and replacing the gear shift mechanism of 212
    Adjusting the gearshift mechanism of 212
    Assembly and disassembly of the secondary shaft 213
    Drive shafts. 217
    Parts and components of the drive shaft soŠRUSom VL100 218
    Parts and components of the drive shaft with ŠRUSom VL107 219
    Disassembly of the drive shaft 219
    Drive shaft assembly 220
    5. WHEEL SUSPENSION 221
    Suspension front wheel 221
    Removing and replacing the subframe 221
    Veski installation under the curb weight of 222
    Checking the status of ball bearings 222
    Removing and replacing the bearings šaroaoj 222
    Rotary fist assy with a nave 223
    Removing and replacing front shock absorber 223
    Rear wheel suspension 225
    Repair rear suspension 225
    6. STEERING 227
    Removing and installing the steering wheel 227
    Removing and replacing the multi-function steering wheel 227
    Steering column 228
    Removal and installation steering traction 229
    Steering gear with hydraulic booster of 229
    Removing air from the steering system 230
    Repair of steering gear 231
    Rotor pump of hydraulic booster steering 231
    Ruleeoj mechanism with electromechanical amplifier 232
    Removal and installation steering traction 233
    7. BRAKES 235
    Technical characteristics of 235
    Front brake repair, brake caliper FS III 236
    Removing and replacing the brake pads 237
    Removing and installing brake calipers 237
    Repair brake calipers FS l! l 238
    Front brake repair, brake caliper FN 3238
    Removing and replacing the brake pads 239
    Removing and installing brake calipers 240
    Repair brake calipers FN 3240
    240 rear brakes
    Adjust parking brake 242
    Parts and components of brake booster/master brake cylinder 243
    Parts and components of 244 brake booster vacuum pump
    Stability system ESP 245
    Electrical and electronic components systems 246
    Fault indication warning lamp with 248
    8-392.
    Exterior trim items 251
    Supervisory body dimensions 257
    Sizes of backlashes between body parts 262
    THE ELECTRICAL CONNECTIONS
    [collapse]



    Issue: 2008
    Author: S. Khodakovsky, A. Leshik
    Genre: Guide to repair and maintenance,
    Publisher: «Company Avtomaster»
    ISBN: 978-966-8520-17-4


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