Diesel car engine Volkswagen Caddy 3

Technical characteristics of 1.9 L and 2.0 L diesel engines
From the engine specifications below, it is clear that the manufacturer has prepared 5 types of diesel engines, differing in volume, power and environmental performance. The...

Timing drive components and parts
List of timing drive components and parts with technological notes on repairs to Figure VC3.001: 1. Upper part of the timing belt cover. 2. Camshaft timing pulley hub fastening...

Auxiliary unit drive
Cars with air conditioning List of units and parts of the auxiliary drive mechanisms with technological notes on repairs to Figure VC3.002: 1. Torsional vibration damper -...

Cylinder block and related components
List of units and parts installed on the cylinder block, with technological notes on repairs to Figure VC3.003: 1. Cylinder block. 2. Gasket: - replace with a new one during...

Removal and installation a poly V-belt
Removal 1. Remove the soundproofing casing. 2. Remove the fuel filter from its mount and, without disconnecting the hoses, set it aside. 3. Mark the direction of movement of the...

Removal and installation the sealing flange and flywheel
List of crankshaft seal parts with repair notes for Figure VC3.008: 1. Front crankshaft oil seal: - do not additionally lubricate the working edge of the sealing ring; - Before...

Cylinder block for diesel engines 1.9 and 2.0 l BDJ, BST, BJB, BSU, BLS
Specification of cylinder block parts for 1.9 and 2.0 L diesel engines BDJ, BST, BOV, BSU, BLS to figure VC3.009 Pos. Part number Name Note Pcs. Cylinder block with pistons and...

Removal and installation the crankshaft speed sensor (G28)
1. Remove the soundproofing casing. 2. Using clamps, clamp the cooling system (coolant) hoses leading to the oil radiator and disconnect them. 3. Remove the oil radiator. 4....

Crankshaft and main bearings
Specification of crank mechanism parts for 1.9 and 2.0 l diesel engines BDJ, BST, BJB, BSU, BLS to figure VC3.011: Pos. Part number Name Note Pcs. 1 038 105021 Q Crankshaft BDJ,...

Crank mechanism parts
List of crank mechanism parts with technological notes on repairs to figure VC3.012: 1. Inserts 1, 2, 4 and 5: - without a lubrication groove, installed in main bearing caps; -...

Connecting rod and piston group
List of parts of the piston group with technological notes on repair to figure VC3.013: 1. Piston rings: - the ring locks must be positioned at an angle of 120° relative to each...

Checking the thermal seal of piston rings
Place the ring on top of the cylinder and then slide it (using an old piston) it into the bottom of the cylinder so that it is positioned at a distance of approximately 15 mm from...

Checking the height clearance between the groove and the ring
Clean the ring groove before checking. Piston ring Dimensions New Maximum permissible value 1st compression ring 0.06-0.09 mm 0.25 mm 2nd compression ring 0.05-0.08 mm 0.25 mm Oil...

Checking the cylinder diameter
Take measurements crosswise in three places in the transverse (A) and longitudinal (B) directions. Deviations from the nominal dimensions should not be more than 0.10 mm. Caution!...

Mounting position and alignment of pistons to cylinders
Please note: The new piston crown is marked with paint indicating the corresponding cylinder numbers. Pistons in cylinders 1 and 2 (designation 1/2): large recess in the piston...

Measuring the protrusion of pistons from the cylinder block at TDC
When installing new pistons or replacing the cylinder block assembly, it is necessary to check the piston protrusion at TDC. The appropriate gasket is selected based on the...

Cylinder head gasket markings
Part number according to the catalogue (arrow 1). Control code (arrow 2) (it doesn't matter for repair work, you shouldn't pay attention to this code). The number of holes codes...

Cylinder head for diesel engines 1.9 and 2.0 l BDJ, BST, BJB, BSU, BLS
Attention! When installing a cylinder head from the exchange stock with the camshaft installed, the friction surfaces of the valve tappets and camshaft cams should be lubricated....

List of parts and assemblies of the cylinder head
List of cylinder head parts and assemblies with technological notes on repairs to figure VC3.021: 1. Upper part of the timing belt cover. 2. Timing belt: - Before removing, mark...

Checking the cylinder head for warpage
Maximum allowable curvature: 0.1 mm.

Installing the valve cover
If there is any damage, replace the cylinder head cover seal and screw seal. Apply sealant to both joints of the support cover and the cylinder head at the front (diameter: approx...

Removal and installation the cylinder head
Attention! Since 05.2005 a modified front (right in the direction of the vehicle) an engine mount that no longer requires removal when replacing the timing belt. The figures below...

Camshaft, valves and pump-injector drive
Caution! Cylinder heads with cracks between the valve seats can be used without reducing engine life if the crack width does not exceed 0.5 mm. Specification of cylinder head...

List of components and parts of the valve mechanism
List of valve mechanism components and parts with technological notes on repairs to Figure VC3.036: 1. Rocker arm axle mounting screw: 20 Nm and tighten by 1/4 turn (90°): -...

Checking the axial run-out of the camshaft
The measurement is taken with the tappets removed and the first, third and last bearing caps installed. Maximum permissible value: no more than 0.15 mm. Apply a thin, even layer...

Valve sizes
Attention! Valves cannot be machined. Only lapping of valves is allowed. Size Inlet valve Exhaust valve Diameter a 35.95 mm 31.45 mm Diameter b 6,980 mm 6.956 mm with 89.95 mm...

Removal and installation the camshaft
Removal 1. Remove the timing belt from the camshaft timing pulley. 2. Remove the retainer. 3. Unscrew the mounting screws (1) securing the camshaft pulley. 4. Remove the toothed...

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Caddy 3 Beetle LT 2D LT 28