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Topic: Repair manual car Volkswagen Caddy (2003-2008).
  1. #1
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    Repair manual car Volkswagen Caddy (2003-2008).    



    Volkswagen Caddy 2003-2008-repair, maintenance and operation of the vehicle.
    In this book, based on original information models, with the 2003 model year.
    This guide contains general information about the structure of the various modifications of the car, maintenance tips, description of all systems of the engine, 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 models, with the 2003 model year. Guide contains a description of 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 engine and pump-jets);
    2.0 l SDI (BDJ, BST (51 kW), without a turbocharger, with pump-jets),
    with mechanical gear transmission.
    This guide contains general information about the structure of the various modifications of the car, maintenance tips, description of all systems of the engine, 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 mechanical gearbox and one section-the drive shafts;
    -Wheel Suspension;
    -Steering;
    -Brake system;
    -Body (c) a detailed description of the inspection dimensions required for the repair works and illustrations for installation of interior finishing elements;
    Diagram of electrical connections and the full list of items of electrical equipment.
    [collapse]


    Guide contains a description of 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:

    Car maintenance-complex control and repair action, carried out at regular intervals during the life of the car and with the aim of maintaining 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 are made of materials and parts replacement and other maintenance work. List of inspection and maintenance work is optimized and compiled on the basis of the analysis of the performance of the car, which continuously held by experts of the company-manufacturer.
    The frequency of conducting works on the defined terms of the so called something for which there is a different frequency. These conditions are the basic conditions that depend on original equipment car. Deviation from the prescribed conditions of operation leads to a change of conditions for the reduced service schedule mileage or service period.
    -To identify the conditions of the test vehicle, as indicated on the label with the data of car: QG1 OG2 or QG0. PR number specifies service 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 configuration rules service means QG1 LongLife. QG2 or QG0 means the service intervals are defined depending on the mileage or time without increasing mileage, unlike rules LongLife.
    [collapse]


    Contents:

    INSTRUCTIONS for USE 9
    An overview 9
    Driver: 9
    The instrument cluster 9
    Lights in dash 10
    Multifunction display in the instrument cluster 11
    Odometer, average speed and fuel consumption 12
    Environmental temperature indicator 12
    Indicator lights 12
    The multifunctional display menu 12
    Set of keys to the vehicle 14
    Central locking switch 15
    Remote control central locking system 15
    Device protecting from opening sliding door children 15
    Lighting 16
    Dash Panel illumination and lighting switch 16
    Tilt-beam headlights 16
    Control wipers 16
    Exterior mirrors 17
    Seat heating 17
    Emergency stop sign and a dressing material 17
    Heating cabin 17
    Driving a car 18
    Tilt steering wheel (if provided) 16
    18 safety
    Traction control (ASR) 19
    Ignition switch and lock devices with an antitheft device 19
    Fuse 19
    Fuses (SC) in the block under the left front panel 19
    Fuses (SB), located in the electronics box in the engine compartment on the left 21
    Location relay fuse, May 24, 2005
    Fuses (SA) block on the BATTERY 24
    Fuses (SB), located in the electronics box in the engine compartment on the left 24
    Fuses (SC) in the 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
    Inspection 34
    Preparatory work prior to the 34
    Lift the car on the lift platform and the Jack 34
    Visual inspection of the BATTERY 34
    Check the level of electrolyte and BATTERY 35
    Check the BATTERY voltage with no load 35
    Tyres: check the status of the paintings wear, tread height pressure 36
    Check 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 the tie rod ends for play, fastening 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 components in the engine compartment (top and bottom) for leaks and damage 38
    Check engine oil level 38
    Check the status of the antifreeze and coolant level cooling system 38
    Poly-v-belt: check the status of the 39
    Check the positioning of the electric window 39
    Run the test drive 40
    Of the 41
    Removal and installation of 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
    Removal and installation of the upper casing of engine 44
    Replacing the fuel filter in a diesel engine 45
    Replacement filter element
    air filter-46.
    Check the status of the toothed belt camshaft drive (4-cylinder petrol engines) 47
    Check the status of the toothed belt camshaft drive (SDI engines and only TOÏ) 47
    Timing belt replacement timing 48
    Replacement timing remiâ timing 1.4 l petrol engines and BUD 48 8SA
    Timing belt replacement timing belt in the 1.6 l petrol engines, with letter symbols BGU ALL BCF 51
    Timing belt replacement timing belt in diesel engines TDI and SDI 53
    Removal, installation and tensioning the timing belt for a car before 05.2005, 2005 (with installed near the engine) 53
    Removing and installing the timing belt (in vehicles with the engine set well away from the engine) 56
    Replacing the spark plugs 59
    Change oil and filter in b-stulennatoj GEARBOX with double clutch 02Ê 60
    Replacement filter 60
    Oil change 60
    Install the oil level 61
    Check headlight adjustment 61
    2. GASOLINE ENGINES 63
    Technical specifications ...-. 63
    1.4 l petrol engines 64
    Removing and installing engine 1.4 l (FAA and BUD) 64
    Assembly and disassembly of the engine (FAA and BUD) 65
    Belt drives 66
    Removal and installation of the poly-v belt 66
    Block cylinders 1.4 l petrol engines (GSA and BUD) 66
    Removal and installation of the front and back covers of the crankshaft 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 installing the camshafts 79 chassis
    Repair of the valve mechanism 80
    Lubrication system 83
    Lubrication system 83
    Removing and replacing parts lubrication system 83
    System ohlaždenij 86
    Parts and components of hydraulic cooling system 87
    Removing and installing the cooling system components 92
    Cooling items installed on a 92
    Parts and components of the cooling system,
    installed on the engine 93
    Removal and installation of 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 the removal and installation of power systems 95
    Assembly and disassembly of the fuel tank 95
    System off the fuel supply when the collision of 96
    Assembly and disassembly of the fuel manifold with injectors 96
    Air filter for the engine block-letter FAA 97
    Engine air filter housing letter BUD 97
    Cleaning the throttle control unit {J338) 98
    Removing and installing fuel injectors 98
    Exhaust system 100
    Parts and components, engine code GSA 100
    Parts and components, engine code BUD 101
    1.6 l petrol engines (BGU, BSE and BSF) 102
    Removing gasoline engine 1.6 l (letter designations BGU, BSE and 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
    Removal and installation of the poly-v belt 106
    Belt transfer without AC 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
    Install the front cover of the cylinder block 108
    Crankshaft 108
    Šatunno-piston group of 110
    Parts and components of piston-110 šatunno
    Check the cylinders, pistons and piston rings 111
    Check the thermal gap piston rings 111
    Checking the clearance height between Groove and ring 111
    Check the cylinder diameter of 111
    Size pistons and cylinders of 111
    Cylinder head 111
    Parts and components of cylinder heads 111
    Check for the presence of hogging CENTRE 112
    Removal and installation of the CENTRAL 112
    Removal, installation and tensioning the timing belt 113
    The valve mechanism 115
    Parts and components of the valve mechanism 115
    Processing of the contact plane CENTRAL 116
    Dimensions of valves 116
    Machining of valve seats 116
    The intake valve seat processing 116
    Exhaust valve seat processing 117
    Check valve bushing guides 117
    Removing and installing the camshaft 117
    Camshaft, verification of 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 systems s cooling 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 components of the air system daigatelej BGU, BSE, BSF 124
    Parts and components of the fuel manifold with injectors for engines 1.4 l GSA 8UD and 1.6 l, BGU.BSE.BSF 126
    Parts and components of supply systems and air filtration 127
    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 of 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 characteristics of diesel engine 1.9 l with alphabetic symbols BJB, BSU, BLS 133
    Technical characteristics of diesel engine 2.0 l with alphabetic symbols 8DJ, BST 133
    134 repair engine
    Drive support mechanisms of 134
    The cylinder block and the associated nodes 135
    Removal and installation of the poly-v belt 135
    Belt drive without AC compressor 136
    Belt drive air compressor with 136
    Removal and installation of the cylinder end cover and flywheel 136
    Crankshaft and bearings, 139
    Šatunno-piston group 140
    Check the thermal gap piston rings 141
    Checking the clearance height between Groove and ring 141
    Check the cylinder diameter 141
    The correct installation position of the piston cylinders and line 142
    Measurement of piston protrusion of the cylinder at TDC 142
    Marking gaskets cylinder head 142
    Size pistons and cylinders of 142
    Parts and components of engine cylinder head 142
    Check GBCna for hogging 146
    Removing and replacing the cover CENTRAL 146
    Removing and replacing the cylinder head 146
    Repair of the valve mechanism 148
    Camshaft, valves and pump-injector units 148
    Verification of the axial run camshaft 150
    Dimensions valve 150
    Removing and installing the camshaft 150
    System smaèki 151
    Pressure oil lubrication bearing turbocharger 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 the 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 turbocharging 179
    Fuel injection system 180
    Specification of the pump-injectors for diesel engines 1.9 l with SGB.BLS.BSU, and 2.0 l diesel engines VCS, 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 letter symbols: BJ8, BSU 182
    Parts and components of the exhaust system catalyst engines-letter; BLS 183
    Parts and components of the system vypusha with diesel particulate filter. Engine code BLS 183
    EGR 185
    Muffler with 186
    4. TRANSMISSION 189
    189 General information
    Clutch 190
    Repair mechanism clutch 190
    Gear 191
    Gear box 191
    Removal of 191
    Install PPC 0AN 192
    Assembly and disassembly of the PPC 0AN 194
    Removing and replacing the cover of Carter gearbox and gears 5-th transfer 195
    Removal and installation of Carter GEARBOX 196
    Removal and installation of the secondary shaft, shaft, differential 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
    Building PPC type 210 0A4
    Gear 211
    Removing and replacing the gear 212
    Adjusting the gear 212
    Assembly and disassembly of the secondary shaft 213
    Drive shafts is. ... 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
    Installing under veski to the curb weight of 222
    Checking ball joints 222
    Removal and installation of šaroaoj supports 222
    Steering knuckle with the Hub Assembly 223
    Removing and replacing front shock absorber 223
    Rear wheel suspension 225
    Repair rear suspension 225
    6. STEERING 227
    Removal and installation steering wheel 227
    Removing and replacing the multi-function steering wheel 227
    Steering column 228
    Removing and replacing the tie rod end 229
    Steering gear with hydraulic booster 229
    Removal of air from the steering system 230
    Repair of steering gear 231
    Rotary pump hydraulic power steering 231
    Ruleeoj mechanism with electromechanical amplifier 232
    Removing and replacing the tie rod end 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 caliper 237
    Repair brake caliper FS l! l 238
    Front brake repair, brake caliper FN 3238
    Removing and replacing the brake pads 239
    Removing and installing brake caliper 240
    Repair brake caliper FN 3240
    Rear 240
    Adjust parking brake 242
    Parts and components of brake booster/master cylinder 243
    Parts and components of 244 brake booster vacuum pump
    Stability control ESP 245
    Electrical and electronic components systems 246
    Fault indication warning lamp with 248
    8-392.
    Elements of the Interior body 251
    Supervisory body dimensions 257
    The size of the gaps between body parts 262
    THE ELECTRICAL CONNECTIONS
    [collapse]



    Release: 2008
    Author: S. Khodakovsky, A. Leshik
    Genre: Guide to car repair and maintenance
    Publisher: "Avtomaster"
    ISBN: 978-966-8520-17-4/DjVu/DOC (fully recognized)
    Quality: the recognized text (OCR)
    Number of pages: 304/300


    Руководство по ремонту и обслуживанию автомобиля Volkswagen Caddy (2003-2008).-e17df6b7712c049edd0781d6915b802d-jpg Руководство по ремонту и обслуживанию автомобиля Volkswagen Caddy (2003-2008).-a4b9dd5d1d6ccdd57b34555dd14a4478-jpg Руководство по ремонту и обслуживанию автомобиля Volkswagen Caddy (2003-2008).-679610ee905ffa9788f8bbef4cb6ea11-jpg





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  2. #2
    Newbie
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    Users Country Flag saad116 на пути к лучшему
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    23.09.2011
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    This text was not translated, because it is originally in English i download this file butt its for russia language can you tell me where i find same manual for english language
    thank



  3. #3
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    Users Country Flag AutoMAN отключил(а) отображение уровня репутации
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    saad116-unfortunately, the manual for Volkswagen Caddy on the portal in Russian

    gentaco likes this.

  4. #4
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    руководство по ремонту, каталог запасных частей, инструкция по ремонту, руководство пользователя
    Translated text
    thankssssssssssssssssss
    Original text



  5. #5
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    руководство по ремонту, каталог запасных частей, инструкция по ремонту, руководство пользователя
    Translated text
    GRACIASSS.... THANKSS
    Original text



  6. #6
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