00 –Technical data
1Safety information
(VRL013736; Edition 12.2019)
⇒ “1.1 Safety regulations for working on fuel supply”, page 1
⇒ “1.2 Safety measures when working on vehicles with a start/ stop system”, page 1
⇒ “1.3 Safety precautions when using testers and measuring in‐struments during a road test”, page 2
⇒ “1.4 Safety precautions when working on the cooling system”, page 2
⇒“1.5Safetyprecautionswhenworkingonignitionsystem”,page 2
⇒ “1.6 Safety precautions when working on exhaust system”, page 3
1.1Safety regulations for working on fuel supply
Risk of injury from highly pressurised fuel.
The fuel system is pressurised. Injury from fuel spray possible.
Before opening the fuel system:
–Wear protective goggles.
–Wear protective gloves.
– Toreleasepressure,wrapacleanclotharoundtheconnection and carefully loosen the connection.
Procedure for releasing pressure in high pressure fuel system ⇒ Rep. gr. 20 ; Fuel tank; Releasing pressure in high pressure fuel system
Danger of fire caused by escaping fuel
Whenthebatteryisconnectedandthedriverdooropens,thedoor contact switch activates the fuel pump. Escaping fuel can ignite and cause a fire.
–Disconnect voltage supply to fuel pump before opening the fuel system.
1.2Safety measures when working on ve‐hicles with a start/stop system
Note the following when working on vehicles with a start/stop system:
Risk of injury due to unexpected motor start
If the vehicle’s start/stop system is activated, the engine can start unexpectedly. A message in the dash panel insert indicates whether the start/stop system is activated.
–Deactivate start/stop system by switching off the ignition.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Caddy 2016 ➤ 3-cylinder
- Edition 12.2019 1. Safety information 1
direct-injection engine (1.0 l engine, 4V, EA 211)
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
1.3Safety precautions when using testers and measuring instruments during a road test
Risk of injury caused by unsecured testing and measuring instru‐ments
When the front passenger airbag is triggered in an accident, in‐sufficiently secured testing and measuring instruments become dangerous projectiles.
–Secure testing and measuring instruments on the rear seat. or
– Have a second person operate the test and measuring equip‐ment on the rear seat.
1.4Safety precautions when working on the cooling system
Danger of scalding by hot coolant
On a warm engine, the cooling system is under high pressure. Danger of scalding by steam and hot coolant.
–Wear protective gloves.
–Wear protective goggles.
–Reduce excess pressure by covering cap of coolant expan‐sion tank with cloths and opening it carefully.
1.5Safety precautions when working on ignition system
Risk of injury due to electric shock
The ignition system is under high voltage when the engine is run‐ning.Touchingtheignitionsystemmayresultinanelectricshock.
– Do not touch or disconnect ignition cables when the engine is running or being turned at starter speed.
Risk of damage to components
Connecting or disconnecting electric cables or washing the en‐gine while it is running may damage components.
– Switchofftheignitionbeforeconnectingordisconnectingelec‐tric cables.
–Switch off the ignition before washing the engine.
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
thgirypocybdetcetorP
2 Rep. gr.00 - Technical data
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
1.6Safety precautions when working on exhaust system
Risk of poisoning due to chemical substances
Exhaust gas temperature senders may contain chemical sub‐stances. There is a risk of poisoning or injuries to respiratory system.
–Never open an exhaust gas temperature sender by cutting, sawing or any other means.
Risk of injury due to hot condensate and particles in the exhaust system.
The exhaust system could contain hot condensate and/or parti‐cles. There is a risk of injury to the eyes, skin and respiratory system, as well as poisoning.
–Always wear protective gloves and eye protection when cut‐ting the exhaust system.
–When cutting, use an extraction system or otherwise ensure sufficient ventilation.
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni
thgirypocybdetcetorP
.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
1. Safety information 3
3-cylinder direct-injection
2Identification
⇒ “2.1 Engine number/engine data”, page 4
2.1Engine number/engine data
Four digit engine codes
The engine code and the engine number can be found on the sticker -arrow- on the upper toothed belt guard.
The engine code is also on the vehicle data sticker and on the crankcase above the gearbox.
Theenginenumberconsistsofupto9characters(alphanumeric).
The first part represents the “engine code”.
The second part (six digit) represents the “serial number”.
If more than 999,999 engines were produced with the same code letters, the first of the six digits are replaced by a letter.
The first 3 digits refer to the mechanical configuration of the en‐gine. They are stamped onto the engine.
The fourth digit denotes the power output of the engine and de‐pends on the engine control unit - J623- .
Note
Fittinglocationsofvehicledatasticker⇒Maintenance;Booklet 40;General;Vehicledatasticker.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Engine code CHZG DKRD DKRE Exhaust emission standard EU6 plus EU6 AG/H/I EU6 AG/H/I Displacement cm3 999 999 999 Power kW at rpm 75/ 5000-5500 62/ 5000-5500 75/ 5000-5500 Torque Nm at rpm 175/ 1500-3500 175/ 1500-3000 175/ 1500-3000 Bore Diam eter, mm 74.5 74.5 74.5 Stroke mm 76.4 76.4 76.4 Compression ratio 10.5:1 10.5:1 10.5:1 RON At least 95 95 95 Firing order 1-2-3 1-2-3 1-2-3 Valves per cylinder 4 4 4 Charging Turbo‐charger Turbo‐charger Turbo‐charger
Caddy 2016 ➤
4 Rep. gr.00 - Technical data
engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
3Repair notes
⇒ “3.1 Rules for cleanliness”, page 5
⇒ “3.2 General information”, page 6
⇒ “3.3 Foreign objects in engine”, page 6
⇒ “3.4 Contact corrosion”, page 7
⇒ “3.5 Routing and attachment of lines”, page 7
⇒ “3.6 Fitting radiator and condensers”, page 7
⇒ “3.7 Checking vacuum system”, page 7
3.1Rules for cleanliness
⇒ “3.1.1 Rules for cleanliness when working on fuel supply sys‐tem/injection system”, page 5
⇒ “3.1.2 Rules for cleanliness when working on turbocharger”, page 6
3.1.1Rules for cleanliness when working on fuel supply system/injection system
When working on the fuel supply/injection system, pay careful at‐tention to the following “7 rules”:
♦ Thoroughly clean all joints and surrounding areas before dis‐mantling.
♦ Place removed parts on a clean surface and cover them over. Use lint-free cloths only.
♦ Carefully cover opened components or seal them if repairs cannot be carried out immediately.
♦ 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.
♦ Make sure that no fuel gets onto the fuel hoses. Should this occur, the fuel hoses must be cleaned immediately.
♦ Protectdisconnectedelectricalconnectorsfromdirtandwater, and reconnect them only when dry.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Caddy 2016 ➤
3. Repair notes 5
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
3.1.2Rules for cleanliness when working on turbocharger
Note
♦ Ifamechanicalfaultisfoundontheturbocharger,e.g.ade‐stroyedcompressorimpeller,justrenewingtheturbocharger isnotenough.Toavoidsubsequentdamage,thefollowing workmustbecarriedout:
♦ Checkairfilterhousing,airfilterelementandintakehosesfor dirt/soiling.
♦ Checkthewholechargeairpathandchargeaircoolerforfor‐eignobjects.
♦ Ifforeignobjectsarefoundinthechargeairsystem,thecharg‐edairroutingmustbecleanedandthechargeaircoolermust berenewed,ifnecessary.
3.2General information
♦ The engine control unit has a self-diagnosis capability. Before carrying out repairs and for fault finding, first read event mem‐ory.Alsothevacuumhosesandconnectionsmustbechecked (unmetered air).
♦ For trouble-free operation of electrical components, a voltage of at least 11.5 volts is necessary.
♦ Do not use sealants containing silicone. Particles of silicone drawn into the engine will not be burnt in the engine and dam‐age the Lambda probe.
♦ Vehicles are fitted with a crash fuel shut-off circuit. It reduces the danger of a fire in a crash as the fuel pump is switched off via the fuel pump relay.
♦ The system also improves the starting characteristics of the engine.Whendriverdoorisopened,thefuelpumpisactivated for 2 seconds to develop pressure in the fuel system.
3.3Foreign objects in engine
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-
Note
Topreventtheingressofforeignbodiesduringworkontheen‐gine,sealopenchannelsoftheintakeandexhaustsectionswith suitableplugs,forexamplefromtheenginebungset-VAS6122-.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
6 Rep. gr.00 - Technical data
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
3.4Contact corrosion
Contact corrosion can occur if unsuitable connecting elements (screws, bolts, nuts, washers, etc.) are used.
For this reason, only connecting elements with a special surface coating have been fitted.
There are also certain rubber or plastic parts made of electrically non-conductive materials.
If there is any doubt about the suitability of parts and their mate‐rials, use new parts ⇒ Electronic Parts Catalogue (ETKA) .
3.5Routing and attachment of lines
Risk of damage to lines
Lines may become damaged by moving or hot components.
–Route lines in their original positions.
– Make sure there is sufficient clearance between the lines and moving or hot components.
3.6Fitting
Note
♦ Eventhoughradiators,condensersorchargeaircoolersare installedcorrectly,thefinsmayexhibitslightindentations.
♦ Thisdoesnotmeanthatthecomponentsaredamaged.
♦ Replacementofthecomponentsduetotheseminorindenta‐tionsisnotpermitted.
3.7Checking vacuum system
Special tools and workshop equipment required
♦ Hand operated vacuum pump - VAS 6213-
Sequence of operations
– Check all vacuum lines throughout entire vacuum system for:
♦ Cracks
♦ Marten bites
♦ Crushing
♦ Porous areas and other leaks
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG.
AGdoesnotguaranteeoracc litywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Volkswagen
radiator and condensers
3. Repair notes 7
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
– Check vacuum line to solenoid valve and from solenoid valve to relevant component.
–If an entry is stored in the event memory, check all vacuum lines leading to the corresponding component and also check the remaining vacuum lines leading to other components.
– Ifpressurecannotbebuilt-upusinghandvacuumpump-VAS 6213- or pressure immediately drops again, check hand vac‐uum pump and connecting hoses for leaks.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
8 Rep. gr.00 - Technical data
10 –Removing and installing engine
1Removing and installing engine
⇒ “1.1 Removing engine”, page 9
⇒ “1.2 Separating engine and gearbox”, page 15
⇒ “1.3 Securing engine on engine and gearbox support”, page 16
⇒ “1.4 Installing engine”, page 18
1.1Removing engine
Special tools and workshop equipment required
♦ Engine support - T10483-
♦ Engine bung set - VAS 6122-
♦ Engine and gearbox jack - VAS 6931-
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen A t ywith respect t o t h e c o r r e c t n e ss o f nininoitamrof ucodsih
3-cylinder direct-injection engine (1.0 l engine, 4V, EA
12.2019 1. Removing and installing engine 9
Caddy 2016 ➤
211) - Edition
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
Removing Note
♦ Theengineisremoveddownwardstogetherwiththegearbox.
♦ Thebatteryearthmustbedisconnectedfortheremainingpro‐cedure.Checkwhetheracodedradioisfitted.Thenobtain anti-theftcodingfirstifnecessary.
–Disconnect connector -3- from vacuum sender - G608- -1-.
– Carefully pull non-return valve -2- together with vacuum send‐er - G608- -1- out of brake servo.
–Remove air filter housing ⇒ page 210
– Removebatteryandbatterytray⇒ Electricalsystem;Rep.gr. 27 ; Battery; Removing and installing battery tray .
–Drain coolant ⇒ page 144
–Remove front left and right wheel housing liner ⇒ General body repairs, exterior; Rep. gr. 66 ; Removing and installing front wheel housing liner .
Continued for vehicles with air conditioning system
NOTICE
Risk of damage to refrigerant line.
Do NOT stretch, kink or bend lines and hoses.
– Prevent damage to condenser and refrigerant lines and ho‐ses.
– The air conditioning system lines must not be opened.
– Remove air conditioner compressor: ⇒ Heating, air condition‐ing; Rep. gr. 87 ; Air conditioner compressor; Removing and installing air conditioner compressor from and on bracket .
–Secure air conditioner compressor -1- in position with wire -2-.
Continued for all vehicles
thgirypocybdetcetorP
–Separate electrical connector -2- of terminal 50.
–Push back cover for battery positive terminal -1-, and unbolt battery positive cable from solenoid switch.
la rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG
ywi t htnin
. icremmocroetavirprofgniypoC
Volksw
12 Rep. gr.10 - Removing and installing engine
3-cylinder direct-injection engine (1.0 l engine, 4V, EA
–Separate electrical connector -1- for reversing light switchF4- .
–Disconnect electrical connector -2-.
–Remove selector mechanism from gearbox ⇒ Rep. gr. 34 ; Selector mechanism; Removing and installing selector mech‐anism .
Note
Theclutchslavecylinderisremovedwiththehoselineconnected andthentiedup.
–Unclip hose line -1- for clutch slave cylinder on holder -2-.
–Swing hose line -1- for clutch slave cylinder in -direction of arrow-.
–Unscrew bolts -1- for clutch slave cylinder -2-.
–Tie up clutch slave cylinder -2- with hose line connected.
–Remove subframe together with steering rack ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and installing subframe with steering rack .
–Remove bolts -arrows- for heat shield.
–Remove heat shield for right drive shaft.
–Disconnect left and right drive shaft from gearbox and tie up ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
la rup op s e s , i n p a r t o r in w hole,
thgirypocybdetcetorP . icremmocroetavirprofgniypoC
isnotpermittedunlessauthorisedbyVolkswagen
s o f
AG. Volkswagen
AGdoesnotguaranteeoracceptanylia
.GAnegawskloVybthgirypoC.tnemucods
Caddy 2016 ➤
211) - Edition 12.2019
13
1. Removing and installing engine
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211)
–Loosen nuts -arrows- of clamping sleeve.
–Pull exhaust pipe towards rear.
–Push engine support - T10483- to stop into holes -arrows- in cylinder block.
–Tighten bolts -1- by hand first.
–At first, tighten bolt -arrow- hand-tight.
- Edition 12.2019
–Tighten bolts -arrows- to 20 Nm.
– Tighten all bolts of engine support - T10483- on cylinder block to 20 Nm.
– Position engine and gearbox jack - VAS 6931- on engine sup‐port - T10483- .
–Raise engine with gearbox slightly.
Note
Tounscrewboltsforassemblymountingusecommerciallyavail‐ablestepladder.
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
e c t
thgirypocybdetcetorP
AG Volkswagen AGd otguaran
.GAnegawskloV
14 Rep. gr.10 - Removing and installing engine
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Unscrew bolts -arrows- of engine mounting -1-.
–Unscrew bolts -arrows- of gearbox mounting.
–First lower engine with gearbox slightly.
– Push gearbox side forwards and only then continue lowering.
Note
♦ Possibilityofdamagetothevacuumlinesorelectricalwiring andtotheenginecompartment.
♦ Checkthatallvacuumlinesandelectricalwiringbetweenen‐gine,gearbox,subframeandbodyhavebeendetached.
–Carefully lower engine and gearbox.
–To prevent fluids from escaping, seal the affected holes with bungs from engine bung set - VAS 6122- .
1.2Separating engine and gearbox
⇒ “1.2.1 Separating engine and gearbox, vehicles with manual gearbox”, page 15
1.2.1Separating engine and gearbox, vehi‐cles with manual gearbox
Special tools and workshop equipment required
♦ Hook - 10 - 222 A /12-
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e GAnegawskloVybthgirypoC.tne
AG Volkswagen
1. Removing and installing
15
engine
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
♦ Workshop hoist - VAS 6100-
Sequence of operations
• Engine with gearbox removed and secured on engine and gearbox jack - VAS 6931- with engine support - T10483- .
–Remove starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Removing and installing starter .
–Mount shackle - 10 - 222 A /12- on gearbox.
– Attach hook - 10 - 222 A /12- to workshop hoist - VAS 6100- .
–Remove bolts -1,
Note
Disregarditems-4,5,A-.
7, 8, 9- securing gearbox to engine.
–Detach gearbox from engine.
1.3 Securingengineonengineandgearbox support
Special tools and workshop equipment required
.GAnegawskloVybthgirypoC.tne
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguarante t t o t
2, 3, 6,
16 Rep. gr.10 - Removing and installing engine
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
♦ Lifting tackle - 2024 A-
♦ Engine and gearbox support - VAS 6095-
♦ Workshop hoist - VAS 6100-
Sequence of operations
• Gearbox detached from engine ⇒ page 15
–Attach lifting tackle - 2024 A- on engine and workshop hoistVAS 6100- as shown in illustration.
Note
♦ Inordertomatchtheliftingtackletothecentreofgravityofthe engine,theholesinthehookrailmustbeallocatedasshown intheillustration.
♦ Thesupporthooksandretainingpinsontheliftingtacklemust besecuredwithlockingpins-arrows-.
–Using workshop hoist - VAS 6100- , lift engine off engine bracket - T10483- .
– Secureengineonengineandgearboxsupport-VAS6095A-.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Volkswagen AGdoesnotguaranteeoraccept o f niof GAnegawskloVybthgirypo
17
1. Removing and installing engine
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
1.4Installing engine
Special tools and workshop equipment required
♦ Engine support - T10483-
la rup op s e s , i n p a r t o r in w hole,
♦ Torque wrench - V.A.G 1332-
♦ Engine and gearbox jack - VAS 6931-
Installing
Install in reverse order, noting the following:
• Engine with gearbox removed and secured on engine and gearbox jack - VAS 6931- with engine support - T10483- .
Note
♦ Renewboltsthataretightenedwithturningfurtherangle.
♦ Renewself-lockingnuts,bolts,seals,gasketsandO-rings.
♦ Secureallhoseconnectionswiththecorrecttypeofhoseclips (sameasoriginalequipment)⇒ Electronicpartscatalogue.
♦ Attachcabletiesinallthesameplaceswheninstalling.
thgirypocybdetcetorP . icremmocroetavirprofgniypoC
isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptan nimrof .
18 Rep. gr.10 - Removing and installing engine
Caddy 2016 ➤ 3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
– Check clutch release bearing for wear and renew if necessary (vehicles with manual gearbox).
– Lightly lubricate clutch release bearing, release bearing guide sleeve and splines on input shaft with grease ⇒ Electronic Parts Catalogue (ETKA) .
–Check whether dowel sleeves for centring have been fitted in cylinder block; insert if necessary.
–Insert intermediate plate -1- on sealing flange -arrow B- and push onto dowel sleeves -arrows A-.
–Bolt gearbox to engine at positions -1, 2, 3, 6, 7, 8, 9-.
Note
Disregarditems-4,5,A-.
–Guide engine with gearbox into body.
– First screw in bolts -arrows- for engine mounting -1- onto stop by hand.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen
o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
A oesnotgua
1. Removing and installing engine 19
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–First screw bolts -arrows- for gearbox mountings into stop by hand.
Note
Theboltsaretightenedtotheirfinaltorqueonlyaftertheassembly mountingshavebeenadjusted.
–Adjust assembly mountings ⇒ page 29
–Remove engine bracket - T10483- from engine.
–Install starter ⇒ Electrical system; Rep. gr. 27 ; Starter; Re‐moving and installing starter .
– Installclutchslavecylinder⇒ Rep.gr. 30;Clutchmechanism; Removing and installing clutch slave cylinder .
–Install selector mechanism on gearbox ⇒ Rep. gr. 34 ; Se‐lector mechanism; Removing and installing selector mecha‐nism .
–Install drive shafts ⇒ Running gear, axles, steering; Rep. gr. 40 ; Drive shaft; Removing and installing drive shaft .
–Install heat shield for right drive shaft.
–Install subframe together with steering rack ⇒ Running gear, axles, steering; Rep. gr. 40 ; Subframe; Removing and instal‐ling subframe with steering rack .
Continued for vehicles with air conditioning system
NOTICE
Risk of damage to refrigerant line.
– Do NOT stretch, kink or bend lines and hoses.
– Prevent damage to condenser and refrigerant lines and ho‐ses.
– The air conditioning system lines must not be opened.
Install air conditioner compressor ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Removing and in‐stalling air conditioner compressor .
–Install poly V-belt ⇒ page 36
Continued for all vehicles
–Electrical connections and routing ⇒ Electrical system; Rep. gr. 97 ; Relay carriers, fuse carriers, electronics boxes; Over‐view of fitting locations - relay carriers, fuse carriers, electron‐ics boxes and ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.
–Add coolant ⇒ page 144
–Install battery and battery tray ⇒ Electrical system; Rep. gr. 27 ; Battery; Removing and installing battery .
–Connect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and connecting battery .
–Install air filter housing ⇒ page 210 .
–Connect ⇒ Vehicle diagnostic tester.
–Delete programmed values, and adapt engine control unitJ623- to throttle valve module - GX3- ⇒ Vehicle diagnostic tester.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
–
20 Rep. gr.10 - Removing and installing engine
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Perform vehicle system test ⇒ Vehicle diagnostic tester.
– Finish the vehicle system test so that any event entries stored during assembly can be cleared automatically.
–Carry out road test.
Torque settings
♦ Thespecifiedtorquesareonlyvalidfornutsandboltswhich havebeenslightlygreased,oiled,phosphate-treatedorblackoxided.
♦ Additionallubricantsuchasengineoilorgearoilmaybeused, butdonotuselubricantcontaininggraphite.
♦ Donotusedegreasedparts.
♦ Thetoleranceforspecifiedtorquesvariesby±15%.
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 22
1. Removing and installing engine
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f ni
thgirypocybdetcetorP
.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Note
Component Torquesetting Bolts and nuts M6 9 Nm M7 15 Nm M8 20 Nm M10 40 Nm M12 65 Nm
21
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
2Assembly mountings
⇒ “2.1 Assembly overview - assembly mountings”, page 22
⇒ “2.2 Removing and installing engine mounting”, page 23
⇒ “2.3 Removing and installing gearbox mounting”, page 25
⇒ “2.4 Removing and installing pendulum support”, page 26
⇒ “2.5 Supporting engine in installation position”, page 27
⇒ “2.6 Adjusting assembly mountings”, page 29
⇒ “2.7 Checking adjustment of assembly mountings (engine and gearbox mountings)”, page 31
2.1Assembly overview - assembly mountings
1 - Bolts
❑Qty. 4
❑Renew after removal
❑50 Nm +90°
2 - Bolt
❑Renew after removal
❑60 Nm +90°
3 - Bolt
❑Renew after removal
❑60 Nm +90°
4 - Gearbox mounting
❑ Removing and installing
⇒ page 25
5 - Pendulum support
❑ Removing and installing
⇒ page 26
6 - Bolt
❑Renew after removal
❑Specified torque and tightening sequence
⇒ page 27
7 - Bolt
❑Renew after removal
❑Specified torque and tightening sequence
⇒ page 27
8 - Bolt
❑Renew after removal
❑Specified torque and tightening sequence
⇒ page 27
9 - Bolt
❑Renew after removal
❑Specified torque and tightening sequence ⇒ page 45
10 - Bolt
❑Renew after removal
.GAnegawskloVybthgirypoC.tnemucodsihtninoi
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole,
t
isnotpermittedunlessauthorisedbyVolk
22 Rep. gr.10 - Removing and installing engine
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
❑Specified torque and tightening sequence ⇒ page 45
11 - Engine mounting
❑Removing and installing ⇒ page 23
12 - Support
13 - Bolts
❑Qty. 2
❑Renew after removal
❑20 Nm +90°
14 - Bolt
❑Renew after removal
❑40 Nm +90°
15 - Bolts
❑Qty. 2
❑Renew after removal
❑60 Nm +90°
16 - Bolt
❑Renew after removal
❑40 Nm +90°
17 - Bolt
❑Renew after removal
❑Specified torque and tightening sequence ⇒ page 45
18 - Engine support
❑Removing and installing ⇒ page 42
2.2Removing
Special tools and workshop equipment required
♦ Torque wrench - VAG 1331-
. icremmocroetavirprofgniypoC
rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o
thgirypocybdetcetorP
la
AG
.GAnegawskloVybthgirypoC.tnem
and installing engine mount‐ing
2. Assembly mountings 23
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211)
♦ Torque wrench - VAG 1332-
Removing
Note
Thecoolantexpansiontankisplacedasidewiththehosescon‐nected.
–Disconnect electrical connector -3-.
–Unclip wiring harness from coolant expansion tank -2- and push to one side.
–Unscrew bolts -1-.
–Lay coolant expansion tank -2- to one side.
- Edition 12.2019
–Unscrew bolt -1-.
–Pull filler neck -2- with filler pipe out of washer fluid reservoir -3-.
–Support engine in its installation position ⇒ page 27
isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen
AGdoesnotguaranteeoracceptanyliabilityw
–Unscrew bolts -2-.
–Remove support -1-.
–Unscrew bolts -4- and -5-.
–Remove engine mounting -3- upwards.
Installing
Install in reverse order, noting the following:
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole,
e c t n
.GAnegawskloVybthgirypoC.tnemucodsihtnin
24 Rep. gr.10 - Removing and installing engine
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
Inspect diaphragm for damage
Note
♦ Damagetothediaphragm-arrow-willresultinhydraulicfluid lossandconsequentlyimpairfunctionality.
♦ Ifthediaphragm-arrow-isdamaged,theenginemounting mustberenewed.
–Adjusting assembly mountings ⇒ page 29
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 22
2.3Removing and installing gearbox mounting
Special tools and workshop equipment required
♦ Torque wrench - VAG 1331-
♦ Torque wrench - VAG 1332-
Removing
– Removebatterytray⇒ Electricalsystem;Rep.gr. 27;Battery; Removing and installing battery tray .
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
Volkswagen AGdoesno nicodsihtninoitamrof GAnegawskl
AG
25
2. Assembly mountings
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Unclip wire guide -1- upwards -arrows-, and push it slightly to one side.
–Support engine in its installation position ⇒ page 27
AG. Volkswagen AGdoesnotguaranteeoraccept
–Unscrew bolts -arrows-.
–Remove gearbox mounting -1- upwards.
Installing
Install in reverse order, noting the following:
–Adjusting assembly mountings ⇒ page 29 .
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 22
2.4 Removing and installing pendulum sup‐port
Special tools and workshop equipment required
♦ Torque wrench - VAG 1331-
icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
thgirypocybdetcetorP .
oitam GAnegawskloVybthgirypoC.tnem
26 Rep. gr.10 - Removing and installing engine
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) -
♦ Torque wrench - VAG 1332-
Removing
–If fitted, remove noise insulation ⇒ General body repairs, ex‐terior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
–Loosen bolt -3-.
–Unscrew bolts -1- and -2-.
–Unscrew bolt -3-.
–Remove pendulum support -4- in direction of travel.
Installing
Install in reverse order, noting the following: Note
♦ Therearethreadedinserts,e.g.“Heli-Coil”intheboltingholes forthependulumsupport.
♦ Identification:shoulderalongbeginningofthread-arrow-.
Specified torque and tightening sequence for pendulum support
–Tighten bolts in 3 stages in the sequence shown:
Stage Component Specified torque/turning further angle
1 Bolts -1, 2- 50 Nm
2 Bolt -3- 100 Nm
3 Bolts -1 … 3- Turn 90° further
2.5Supporting engine in installation posi‐tion
Special tools and workshop equipment required
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswage ptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
Caddy 2016 ➤
2. Assembly mountings 27
Edition 12.2019
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
♦ Support - 10 - 222 A-
♦ Adapter - 10 - 222 A /30-
la rup op s e s , i n p a r t o r in w hole,
♦ Adapter - 10 - 222 A /32-
.
♦ Bracket - T10358-
Sequence of operations
–Remove filler pieces from upper edge of left and right wings.
–Remove air pipe ⇒ page 194
–Slide 2 spindles - 10 - 222 A /32- onto support bracket - 10222 A- .
isnotpermittedunlessauthorisedbyVolkswage yliabilitywi
thgirypocybdetceto
icremmocroetavirprofgniypoC
th respect t o t h e c o r r e c t n e ss o f nimucodsihtninoitamrof
28 Rep. gr.10 - Removing and installing engine
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
– Fit support bracket - 10 - 222 A- with adapter - 10 - 222 A /30as shown.
–Engage hook of spindle - 10 - 222 A /32- in left lifting eye.
– Unscrew front bolt for gearbox, and bolt on bracket - T10358as shown in illustration.
– Engage hook of spindle - 10 - 222 A /32- in bracket - T10358as shown.
– Take up weight of engine and gearbox on support bracket via spindles.
2.6Adjusting assembly mountings
Special tools and workshop equipment required
♦ Torque wrench - VAG 1331-
.GAnegawskloVybthg
la rup op s e s , i n p a r t o r in w hole,
t h e c o r r e c t n e ss
thgirypocybdetcetorP . icremmocroetavirprofgniypoC
isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaran
Caddy 2016 ➤
2. Assembly mountings 29
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
♦ Torque wrench - VAG 1332-
Sequence of operations
Note
Thecoolantexpansiontankisplacedasidewiththehosescon‐nected.
–Disconnect electrical connector -3-.
–Unclip wiring harness from coolant expansion tank -2- and push to one side.
–Unscrew bolts -1-.
–Lay coolant expansion tank -2- to one side.
–Unscrew bolt -1-.
–Pull filler neck -2- with filler pipe out of washer fluid reservoir -3-.
– Removebatterytray⇒ Electricalsystem;Rep.gr. 27;Battery; Removing and installing battery tray .
–Support engine in its installation position ⇒ page 27
–Unscrew bolts -2- from engine mounting -1-.
–First screw new bolts in loosely.
thgirypocybdetce . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f nimucodsihtninoitamrof
AG.
30 Rep. gr.10 - Removing and installing engine
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Unscrew bolts -arrows- from gearbox mounting -1-.
–First screw new bolts in loosely.
Using an assembly lever, adjust engine and gearbox so that specifications listed below are attained
Theremustbeadistanceof-b-=10mmbetweenenginesupport
-1- and engine mounting -2-.
Side surface of engine support -1- must be located parallel to support arm of engine mounting -2-.
Dimension -a- must be identical at all measuring points. Note
Distance-b-=10mmcanalsobecheckedwithametalrodof suitablesize,orsimilar.
–Tighten bolts for engine mounting.
On the gearbox side, ensure that the edges of the support arm -2- and gearbox support -1- are parallel.
Dimension -a- must be identical at all measuring points.
–Tighten bolts for gearbox mounting.
Installing
Install in reverse order, noting the following:
Torque settings
♦ ⇒ “2.1 Assembly overview - assembly mountings”, page 22
2.7Checking adjustment of assembly mountings (engine and gearbox mount‐ings)
The following dimensions must be set
Theremustbeadistanceof-b-=10mmbetweenenginesupport -1- and engine mounting -2-.
Side surface of engine support -1- must be located parallel to support arm of engine mounting -2-.
Dimension -a- must be identical at all measuring points.
Note
Distance-b-=10mmcanalsobecheckedwithametalrodof suitablesize,orsimilar.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen A oracceptany it ywith respect t o t h e c o r r e c t n e ss o f ni.tnemucodsihtninoitamrof
Caddy 2016 ➤
2. Assembly mountings 31
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
On the gearbox side, ensure that the edges of the support arm -2- and gearbox support -1- are parallel.
Dimension -a- must be identical at all measuring points.
–If the dimension is too small or too high, adjust assembly mountings ⇒ page 29
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaran r e c t n e ss o f ni.GAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
32 Rep. gr.10 - Removing and installing engine
3-cylinder direct-injection engine (1.0
13 –Crankshaft group
1Cylinder block (pulley end)
⇒ “1.1 Assembly overview - poly V-belt drive”, page 33
⇒ “1.2 Removing and installing poly-V belt”, page 36
⇒ “1.3 Removing and installing tensioner for poly V-belt”, page 39
⇒ “1.4 Removing and installing vibration damper”, page 40
⇒ “1.5 Removing and installing engine support”, page 42
⇒ “1.6 Renewing crankshaft oil seal - belt pulley end”, page 46
1.1Assembly overview - poly V-belt drive
⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles without A/C system”, page 33
⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioning system”, page 35
1.1.1Assembly overview - poly V-belt drive, vehicles without A/C system
1 - Bolts
❑Qty. 2
❑Renew after removal
❑20 Nm +90°
2 - Tensioning device for poly V-belt
❑Lock with locking pinT10060 A- .
❑ Removing and installing
⇒ page 39
3 - Bolts
❑Qty. 2
❑Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; As‐sembly overview - alter‐nator
4 - Alternator
❑With freewheel
❑Various versions of the alternator decoupler pulley, -A- or -B-, may be fitted depending on the type and version of alternator. Allocation
⇒ page 34
❑ ThelengthofthepolyVbelt must be determined accordingtothe⇒ Elec‐tronic Parts Catalogue (ETKA) depending on the version of alternator decoupler pulley.
❑ Removing and installing
i la rup op s e s , i n p a r t o r in w h
Caddy 2016 ➤
l engine, 4V, EA 211) - Edition 12.2019
33
1. Cylinder block (pulley end)
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
5 - Poly V-belt
❑Check for wear
❑Before removing, mark direction of rotation with chalk or felt-tipped pen
❑ The length of the poly V-belt must be determined according to the ⇒ Electronic Parts Catalogue (ETKA) depending on the version of alternator decoupler pulley.
❑Do not kink
❑Removing and installing ⇒ page 36
❑When installing, make sure it is properly seated on pulleys.
❑Poly V-belt routing ⇒ page 37
6 - Vibration damper
❑Contact surfaces must be free of oil and grease.
❑Removing and installing ⇒ page 40
7 - Bolt
❑Renew after removal
❑Contact surface for bolt must be free of oil and grease
❑Oil threads before inserting.
❑Use counter-hold tool - T10475- to loosen and tighten
❑Turning further can be done in several stages.
❑The turning further angle can be measured with a commercial protractor.
❑150 Nm +180°
Allocation of overrunning alternator pulley
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niGAnegawskloVybthgirypoC.tnemucodsihtninoitamrof
34 Rep. gr.13 - Crankshaft group
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
1.1.2 Assemblyoverview-polyV-beltdrive,vehicleswithairconditioningsystem
1 - Bolts
❑Qty. 2
❑Renew after removal
❑20 Nm +90°
2 - Tensioning device for poly V-belt
❑Lock with locking pinT10060 A- .
❑ Removing and installing
⇒ page 39
3 - Bolts
❑Qty. 2
❑Specified torque ⇒ Electrical system; Rep. gr. 27 ; Alternator; As‐sembly overview - alter‐nator
4 - Alternator
❑With freewheel
❑Various versions of the alternator decoupler pulley, -A- or -B-, may be fitted depending on the type and version of alternator. Allocation
⇒ page 34
❑ ThelengthofthepolyVbelt must be determined accordingtothe⇒ Elec‐tronic Parts Catalogue (ETKA) depending on the version of alternator decoupler pulley.
❑ Removing and installing
⇒ Electrical system; Rep. gr. 27 ; Alternator; Removing and installing alternator
5 - Centring sleeves
❑Qty. 2
6 - Air conditioner compressor
❑Assembly overview ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly overview - drive unit of air conditioner compressor .
❑ Removingandinstalling⇒ Heating,airconditioning;Rep.gr. 87;Airconditionercompressor;Removing and installing air conditioner compressor
7 - Bolts
❑Qty. 3
❑ Specified torque ⇒ Heating, air conditioning; Rep. gr. 87 ; Air conditioner compressor; Assembly over‐view - drive unit of air conditioner compressor .
8 - Vibration damper
❑Contact surfaces must be free of oil and grease.
❑Removing and installing ⇒ page 40
9 - Bolt
❑Renew after removal
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG. Vo .GAnegawskl
1.
35
Cylinder block (pulley end)
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
❑Contact surface for bolt must be free of oil and grease
❑Oil threads before inserting.
❑Use counter-hold tool - T10475- to loosen and tighten
❑Turning further can be done in several stages.
❑The turning further angle can be measured with a commercial protractor.
❑150 Nm +180°
10 - Poly V-belt
❑Check for wear
❑Before removing, mark direction of rotation with chalk or felt-tipped pen
❑ The length of the poly V-belt must be determined according to the ⇒ Electronic Parts Catalogue (ETKA) depending on the version of alternator decoupler pulley.
❑Do not kink
❑Removing and installing ⇒ page 38
❑When installing, make sure it is properly seated on pulleys.
❑Poly V-belt routing ⇒ page 39
Allocation of overrunning alternator pulley
1.2Removing and installing poly-V belt
⇒ “1.2.1 Removing and installing poly V-belt, vehicles without air conditioner”, page 36
⇒ “1.2.2 Removing and installing poly V-belt, vehicles with air conditioner”, page 38
1.2.1 Removing and installing poly V-belt, ve‐hicles without air conditioner
Special tools and workshop equipment required
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
AGdoesnotguaranteeoracceptanyliabilitywith respect t o t h e c o r r e c t n e ss o f niinoitamrof
AG Volkswagen
36 Rep. gr.13 - Crankshaft group
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
♦ Locking pin - T10060 A-
Removing
–If fitted, remove noise insulation ⇒ General body repairs, ex‐terior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
–Mark running direction of poly V-belt.
– Turn tensioning device -1- in -direction of arrow- with a 16 mm ring spanner -2- to slacken poly-V belt.
–Lock tensioner -1- in place with locking pin - T10060 A- .
–Release tension from tensioner -1-.
–Remove poly V-belt.
Installing
Install in reverse order, noting the following:
Note
♦ Variousversionsofthealternatordecouplerpulley,-A-or -B-,maybefitteddependingonthetypeandversionofalter‐nator.Allocation⇒page34
♦ ThelengthofthepolyV-beltmustbedeterminedaccordingto the⇒ Electronicpartscatalogue(ETKA)dependingonthe versionofoverrunningalternatorpulley.
–Fit poly V-belt as shown in illustration.
1 -Vibration damper
2 -Tensioning device for poly V-belt
3 -Alternator
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
AGdoesnotguaranteeoracceptanyliabilit GAnegawskloVybthgirypoC.tnemucodsihtninoita
AG Volkswagen
Caddy 2016 ➤
37
1. Cylinder block (pulley end)
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Use a 16 mm ring spanner -2- to turn tensioning device -1- in -direction of arrow-.
–Pull out locking pin - T10060 A- .
–Release tension from tensioner -1-.
–Check that poly V-belt is properly seated.
–Start engine and check belt running.
1.2.2 Removing and installing poly V-belt, ve‐hicles with air conditioner
Special tools and workshop equipment required
♦ Locking pin - T10060 A-
Removing
–If fitted, remove noise insulation ⇒ General body repairs, ex‐terior; Rep. gr. 66 ; Noise insulation; Removing and installing noise insulation .
–Mark running direction of poly V-belt.
– Turn tensioning device -1- in -direction of arrow- with a 16 mm ring spanner -2- to slacken poly-V belt.
–Lock tensioner -1- in place with locking pin - T10060 A- .
–Release tension from tensioner -1-.
–Remove poly V-belt.
Installing
Install in reverse order, noting the following:
Note
♦ Variousversionsofthealternatordecouplerpulley,-A-or -B-,maybefitteddependingonthetypeandversionofalter‐nator.Allocation⇒page36
♦ ThelengthofthepolyV-beltmustbedeterminedaccordingto the⇒ Electronicpartscatalogue(ETKA)dependingonthe versionofoverrunningalternatorpulley.
Install in reverse order, noting the following:
. icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
AGdoesnotguaran e c o r r e c t n e ss o f ninoitamrof
thgirypocybdetcetorP
AG Volkswagen
.GAnegawskloVybthg
38 Rep. gr.13 - Crankshaft group
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Fit poly V-belt as shown in illustration.
1 -Vibration damper
2 -Tensioning device for poly V-belt
3 -Alternator
4 -Air conditioner compressor
Use a 16 mm ring spanner -2- to turn tensioning device -1- in -direction of arrow-.
–Pull out locking pin - T10060 A- .
–Release tension from tensioner -1-.
–Check that poly V-belt is properly seated.
–Start engine and check belt running.
1.3Removing and installing tensioner for poly V-belt
⇒ “1.3.1 Removing and installing tensioner for poly V-belt, vehi‐cles without air conditioner”, page 39
⇒ “1.3.2 Removing and installing tensioner for poly V-belt, vehi‐cles with air conditioner”, page 39
1.3.1Removing and installing tensioner for poly V-belt, vehicles without air condi‐tioner
Removing
–Remove poly V-belt ⇒ page 36
–Unscrew bolts -arrows-.
–Remove tensioning device -1- for poly V-belt.
Installing
Install in reverse order, noting the following:
–Install poly V-belt ⇒ page 36
Torque settings
♦ ⇒ “1.1.1 Assembly overview - poly V-belt drive, vehicles with‐out A/C system”, page 33
1.3.2Removing and installing tensioner for poly V-belt, vehicles with air conditioner
Removing
–Remove poly V-belt ⇒ page 38
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen
AGdoesnotguaranteeoracceptanyliability t GAnegawskloVybthgirypoC.tnemucodsihtninoi
AG. Volkswagen
Caddy 2016 ➤
1.
end) 39
Cylinder block (pulley
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Unscrew bolts -arrows-.
–Remove tensioning device -1- for poly V-belt.
Installing
Install in reverse order, noting the following:
–Install poly V-belt ⇒ page 38 .
Torque settings
♦ ⇒ “1.1.2 Assembly overview - poly V-belt drive, vehicles with air conditioning system”, page 35
1.4 Removingandinstallingvibrationdamp‐
Special tools and workshop equipment required
♦ Counter-hold tool - T10475-
Removing
–Fit inserts - T10475/1- and -T10475/2- to counter-hold toolT10475- as shown in illustration.
–Remove poly V-belt ⇒ page 36 .
Rotate crankshaft to TDC position as follows:
–Using a ratchet -4-, turn crankshaft via centre bolt -3- in -direction of arrow-.
• The TDC position of the crankshaft has been attained, when the marking -arrow- on the vibration damper -1- is properly aligned with the TDC marking on the lower toothed belt guard -2-.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volks eptanyliabilitywith resp
C.tnemucods
er
40 Rep. gr.13 - Crankshaft group
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
2016
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Fit prepared counter-hold tool - T10475- to vibration damper -1-, and counterhold it in clockwise direction.
–Unscrew bolt -arrow- for vibration damper -1-.
–Remove vibration damper -1-.
NOTICE
Risk of damage to engine.
– To avoid disturbing valve timing, do not turn the crankshaft when the vibration damper has been removed.
– If the vibration damper cannot be reinstalled immediately, temporarilylockthecrankshaftpulleyinplaceusingthecen‐tre bolt.
Installing
Install in reverse order, noting the following:
Note
♦ Renewboltsthataretightenedwithturningfurtherangle.
♦ Allcontactsurfacesbetweenbolt,polyV-beltpulleyandcrank‐shaftsprocketmustbefreeofoilandgrease.
–Open line guide -3-.
–Remove fuel hose and coolant hose from line duct.
–Unscrew bolt -2-.
–Release clips -arrows-.
–Remove upper toothed belt guard.
–Make sure that markings -arrows- on vibration damper -1-, crankshafttoothedbeltpulley-2-andlowertoothedbeltguard -3- are properly aligned.
–Fit vibration damper onto crankshaft toothed belt pulley.
thgirypocybdetcetorP . icremmocroetavirprofgniypoCla rup op s e s , i n p a r t o r in w hole, isnotpermittedunlessauthorisedbyVolkswagen AG Volkswagen AGdoesnotguara abilitywith respect t o t h e c o r r e c t n e ss o f nioitamrof GAnegawskloVybth
1.
block (pulley end) 41
Caddy
➤
Cylinder
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211)
• The markings -3- on the camshaft adjuster of the inlet cam‐shaft-1-mustbeproperlyalignedwithweb-2-onthecamshaft housing.
• The marking -3- on the camshaft adjuster of the exhaust cam‐shaft-1-mustbeproperlyalignedwithweb-2-onthecamshaft housing.
–Fit prepared counter-hold tool - T10475- to vibration damper -1-, and counterhold it in anticlockwise direction.
–Tighten bolt -arrow- for vibration damper -1-.
–Install poly V-belt ⇒ page 36 .
Torque settings
♦ ⇒ “1.1 Assembly overview - poly V-belt drive”, page 33
1.5 Removing and installing engine support
GAnegawskloVybthgirypoC.tn
Special tools and workshop equipment required
♦ Engine bung set - VAS 6122-
la rup op s e s , i n p a r t o r in w hole,
thgirypocybdetcetorP . icremmocroetavirprofgniypoC
isnotpermittedunlessauthorisedbyVolkswagen
e c o r
AG Volkswagen AGdoesnotguaranteeoracc
42 Rep. gr.13 - Crankshaft group
- Edition 12.2019
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
♦ Torque wrench - VAG 1331-
♦ Torque wrench - VAG 1332-
Removing
–Remove air pipe ⇒ page 194
–Release high pressure ⇒ page 1 .
– First press hose connector -1- downwards, and then press re‐lease tabs -arrows-.
–Keep release buttons pressed and pull off hose coupling -1-.
Pressreleasetabonhose-2-connectedtoactivatedcharcoal filter.
–Disconnect hose to activated charcoal filter and lay aside.
la rup op s e s , i n p a r t o r in w hole,
– Seal open lines and connections with clean plugs from engine bung set - VAS 6122- .
–Unscrew bolt -1-.
–Push coolant pipe with coolant hose -2- to one side.
. icremmocroetavirprofgniypoC
isnotpermittedunlessauthorisedbyVolkswagen
thgirypocybdetcetorP
anyliabilitywith respect
AG. Volkswagen AGd
nemuc
.GAneg
–
Caddy 2016 ➤
1. Cylinder block (pulley end) 43
Caddy 2016 ➤
3-cylinder direct-injection engine (1.0 l engine, 4V, EA 211) - Edition 12.2019
–Pull vacuum hose -1- off vacuum pump for brakes - V192-A-.
– Disconnect connector -2- on vacuum pump for brakes - V192-A-.
–Remove bolts -arrows- for toothed belt cover (bottom) -1-.
AG. Volkswagen AGdoesnotguaranteeoracce
–Remove tensioner for poly V-belt ⇒ page 39
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery; Disconnecting and reconnecting battery .
–Loosen bolt -1- but do not remove.
–Unscrew bolt -2-.
–Swivel alternator -3- in -direction of arrow-.
–Detach hoses from retainer -3-.
–Unscrew bolt -2-.
–Open clips -arrows-.
–Remove upper toothed belt guard -1-.
la rup op s e s , i n p a r t o r in w hole,
thgirypocybdetcetorP . icremmocroetavirprofgniypoC
isnotpermittedunlessauthorisedbyVolkswagen
n e s
.GAnegawskloVybthgirypoC.tne
44 Rep. gr.13 - Crankshaft group
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
