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Beetle (1960-1986) Caddy 3 (2003-2010)

Gasoline engine 1.6L car Volkswagen Caddy 3

1.6L petrol engines (BGU, BSE and BSF) — design description
1.6 liter petrol engine options Part Number Name Note PC. 06А100039Р Complete engine 75KW 1.6L BGU 1 06A 100098EX* Complete engine 75KW 1.6L BGU 1 06A100043T Complete engine 75KW...

Removing the petrol engine
Attention! When carrying out work, the battery ground wire will be disconnected. Therefore, you must first check whether a radio with coding is installed in the car. If so, the...

Gasoline engine installation
Installation is carried out in the reverse order, observing the following instructions. 1. Install new centering sleeves in the cylinder block (for the correct alignment of the...

Disassembly and assembly of a gasoline engine
Attention! If a large amount of metal chips and other wear products are found in the engine oil during engine repair, this may indicate damage to the connecting rod or main...

Removing the upper part of the casing of the toothed belt
1. Turn the fixing screw (1) so that its slot is vertical. 2. Press up the latches (arrows) and remove the upper part of the toothed belt cover.

Removal and installation of poly V-belt
Removing 1. Remove the acoustic cover. 2. Mark the running direction of the V-ribbed belt. 3. To loosen the poly V-belt, turn the tensioner in the direction of the arrow. For...

Cylinder covers and flywheel
List of parts and assemblies with notes on installation work to Figure VC2.140: 1. Screw of fastening of a forward cover of the block of cylinders: 15 Nm. 2. Front crankshaft oil...

Removal and installation of a back cover of the block of cylinders
Removing 1. Remove the gearbox. 2. Remove the flywheel. 3. Remove the oil pan. 4. Unscrew the cover fixing screws (arrows). Installation Attention: do not lubricate the sealing...

Installation of a forward cover of the block of cylinders
List of parts and assemblies with notes on installation work to Figure VC2.147: 1. Oil pump. 2. Oil pump mounting screw: 15 Nm. 3. Oil pump drive sprocket. 4. Inserts 1, 2, 3, 4...

Removal and installation of the master rotor
Drive rotor (2) replace after each unscrewing of the fixing screws (1). Attention! When re-installing, the holes of the used master rotor are so deformed that the heads of the...

Marking of the upper shells of the main bearings of the crankshaft
The thickness of the liner of each of the bearings is indicated by the letter marking applied on the lower surplus plane of the cylinder block. The arrow points in the direction...

Parts and assemblies of the cylinder-piston and connecting rod-piston groups
The list of elements of the cylinder-piston and connecting rod-piston groups with technological recommendations for repair to Figure VC2.150: 1. Piston rings: - the locks of the...

Mounting position of bearing shells
BGU engines Insert (1) with oil inlet (arrow) installed in the crank. Insert (2) without an oil supply hole, it is installed in the connecting rod bearing cap. Attention! In BSE...

Checking cylinders, pistons and piston rings
Checking the thermal clearance of the piston rings Install the ring from the top into the cylinder and then slide it into the bottom of the cylinder so that it is positioned at a...

Parts and assemblies of the cylinder head
When installing the cylinder head from the exchange fund, lubricate all friction surfaces of the roller levers, roller lever bearings and camshaft cams. Plastic pads protecting...

Checking the cylinder head for warping
Maximum flatness deviation: 0.1 mm.

Removal and installation of cylinder head
Removing 1. Remove the engine cover. 2. Drain the coolant. 3. Remove intake manifold. 4. Unscrew the screws securing the distributor of the cooling system (arrows). 5. Disconnect...

Removal, installation and tension of a toothed belt
Removing 1. Remove the engine cover. 2. Remove poly V-belt. 3. Disconnect the upper hose from the expansion tank of the cooling system. 4. Remove the expansion tank and put it...

Checking the semi-automatic toothed belt tensioner
Mounting position: Retainer (arrow) roller must enter the recess on the cylinder head. Checking procedure Set the crankshaft to the TDC position of the first cylinder. Press...

Parts and assemblies of the valve mechanism
Attention! If there are cracks in the cylinder head between the valve seats, as well as between the valve seat rings and the threaded holes for the spark plugs, and if the width...

Processing of the attached cylinder head plane
Cylinder head machining allowance: size (A) not less than 132.9 mm.

Valve sizes
The valves are not machined. Only lapping of valves is allowed. Valve dimensions Size Inlet valve Exhaust valve Diameter a 39.5±0.15 mm 32.9±0.15 mm Diameter b 5.98±0.007 mm...

Valve seat processing
Attention! When repairing engines with leaky valves, it is not enough to replace the valves or remake the valve seats. It is also necessary, especially for engines with high...

Checking the valve guides
Checking procedure Insert the new valve into the guide sleeve. The end of the valve stem must be closed with a guide sleeve. The intake and exhaust valve stems have different...

Removal and installation of a camshaft
Removing Attention! Mounting planes of the camshaft housing (from below) and cylinder head (above) are not subject to mechanical processing. The camshaft bearings are integrated...

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Caddy 3 Beetle