VAG CAYC — 1.6L I4 16V DOHC CR (common-rail) Engine
1.6L I4 16V DOHC CR (common-rail) · 105 hp · 250 Nm
Values cited from a licensed workshop database.
On the CAYC, flywheel bolts: 60 Nm + 90°.
Engine overview
Manufacturer
VAG
Displacement
1.6 L
Configuration
I4 16V DOHC CR (common-rail)
Power
105 hp
Torque
250 Nm
Production years
2009-2014
Fuel type
Diesel
Vehicles with this engine
Known failures & weak points
Oil pump drive failure: the oil pump on the 1.6 TDI is driven by a small toothed belt inside the oil sump (not a balance-shaft module). The belt can fail, causing sudden oil pressure loss and, if not caught quickly, serious engine damage. Most common around 100,000-150,000 km; VW issued a technical bulletin covering an updated belt.
Timing belt + water pump 90k km / 4 years — interference engine.
EGR cooler clog/crack — common at 100k.
DPF clogs in city use, forced regen needed.
Injector failures (Continental Siemens) at 150k+.
Tandem pump (vacuum + fuel) gasket failure → vacuum loss.
Turbo (KP35-style) actuator wear at 150k.
Common torque specifications
| Head Bolts | M11 — 30 Nm + 90° + 90° + 90° (TTY) unconfirmed |
|---|---|
| Crank Pulley Bolt | 90 Nm + 90° (TTY, M18 stretch bolt) unconfirmed |
| Cam Pulley Bolt | 100 Nm unconfirmed |
| Injector Clamp | 8 Nm + 180° unconfirmed |
| Flywheel Bolts | 60 Nm + 90° |
| Oil Drain Plug | 30 Nm |
Figures marked unconfirmed could not be cross-checked against a workshop source. Verify against the vehicle’s own documentation before tightening.
Factory specifications
Values from the manufacturer documentation for this engine.
Emissions
| Emission code | 715/2007*692/2008A |
| Emission standard | Euro 5 |
| CO2 average | 114 g/km |
| CO | 0.246 g/km |
| NOx | 0.155 g/km |
| HC NOx | 0.180 g/km |
| CO2 average | 109 - 112 g/km |
| CO | 0.253 g/km |
| NOx | 0.158 g/km |
| HC NOx | 0.183 g/km |
| CO | 0.113 g/km |
| NOx | 0.122 g/km |
| HC NOx | 0.141 g/km |
Capacities
| Air-conditioner refrigerant | 525 ± 25 g |
| Air-conditioner compressor oil | 140 ± 10 ml |
| Air-conditioner compressor oil | 110 ± 10 ml |
| Air-conditioner compressor oil | 120 ± 15 ml |
Brakes
| Refer to the type identification on the label | FS III |
| Disc diameter, front | 256.0 mm |
| Disc thickness, front | 22.0 mm |
| Disc thickness, front, min. | 19.0 mm |
| Brake pad thickness, front | 14.0 mm |
| Brake pad thickness, front, min. | 7.0 mm |
| Refer to the type identification on the label | FN3 |
| Disc diameter, front | 288.0 mm |
| Disc thickness, front | 25.0 mm |
| Disc thickness, front, min. | 22.0 mm |
| Disc diameter, rear | 232.0 mm |
| Disc thickness, rear | 9.0 mm |
| Disc thickness, rear, min. | 7.0 mm |
| Brake pad thickness, rear | 11.5 mm |
| Brake pad thickness, rear, min. | 7.0 mm |
| Drum diameter, rear | 200.0 mm |
| Drum lining thickness | 5.4 mm |
| Drum lining thickness, min. | 2.5 mm |
Steering and wheel alignment
| Camber, front | -0°39' ± 30' ° |
| Max. difference left side - right side | 30' ° |
| Castor, front | 5°04' ± 30' ° |
| Toe-in, front | 0°10' ± 10' ° |
| Toe-in, rear | 0°26' ± 10' ° |
| Camber, rear | -1°30' ± 10' ° |
| Camber, front | -0°30' ± 30' ° |
| Camber, front | -0°37' ± 30' ° |
| Camber, front | -0°41' ± 30' ° |
| Camber, front | -0°14' ± 30' ° |
| Camber, front | -0°22' ± 30' ° |
| Castor, front | 7°32' ± 30' ° |
| Castor, front | 7°49' ± 30' ° |
| Castor, front | 7°44' ± 30' ° |
| Castor, front | 7°16' ± 30' ° |
| Castor, front | 7°31' ± 30' ° |
| Castor, front | 7°44' ± 30 ° |
| Toe-in, rear | 0°10' ± 10' ° |
| Max. difference left side - right side | 20' ° |
| Camber, rear | -1°20' ± 30' ° |
| Camber, rear | -1°45' ± 30' ° |
Wheels and tyres
| Tyre size | 175/70 R14 84T |
| Optional | 185/60 R15 84T |
| Optional | 185/60 R15 84H |
| Optional | 215/45 R16 86H |
| Optional | 215/40 R17 87V |
Engine codes in the same family
The same code prefix usually means the same block with a different output, fuel or model year. Procedures are often shared — check the code on the engine plate.
Workshop procedures for this engine
Step-by-step procedures from the workshop database, carrying 224 torque figures.
- Removing and installing camshaft · 47 torque figures
- Removing and installing toothed belt · 31 torque figures
- Securing engine to engine and gearbox support · 18 torque figures
- Removing and installing sealing flange (gearbox end) · 13 torque figures
- Removing and installing high-pressure pump · 16 torque figures
- Renewing sealing flange (gearbox end) · 9 torque figures
- Assembly overview - cylinder head · 13 torque figures
- Removing and installing ancillary bracket · 10 torque figures
- Installing and tensioning toothed belt · 7 torque figures
- Measuring radial clearance of crankshaft · 10 torque figures
- Removing and installing engine mountings · 7 torque figures
- Removing and installing sealing flange on pulley end · 6 torque figures
- Removing and installing 4/2-way valve with thermostat · 5 torque figures
- Renewing vacuum unit for turbocharger · 3 torque figures
- Removing and installing throttle valve module J338 · 6 torque figures
- Removing and installing toothed belt, type A · 2 torque figures
- Removing and installing toothed belt, type B · 2 torque figures
- Removing and installing particulate filter · 3 torque figures
- Installing a new balancer shaft module · 5 torque figures
- 4-cylinder TDI engine (1.6 ltr. 4-valve common rail), mechanics — Removing engine · 1 torque figures
- Removing and installing fuel tank - vehicles with four-wheel drive · 1 torque figures
- Removing engine, Passat · 1 torque figures
- Removing engine, Touran · 1 torque figures
- Measuring radial clearance of camshaft · 6 torque figures
- Removing and installing fuel tank - vehicles with front-wheel drive · 1 torque figures
Service intervals
| Timing Belt Km | 90000 |
|---|---|
| Timing Belt Years | 4 |
| Oil Change Km | 15000 |
| Oil Spec | 5W-30 VW 507.00 (low-SAPS for DPF) |
| Oil Capacity L | 4.3 |
| Coolant Spec | G12++ / G13 |
Pro tips from the field
Oil pump drive belt (inside the oil sump, not a balance-shaft module) — VW issued a technical bulletin covering the updated belt; check service history for whether it has been done.
Use 507.00 oil ONLY (low-SAPS, mandatory for DPF).
Don't extend timing belt past 90k — interference engine, expensive to fix.
CAYC is in tons of Eastern European city cars — common BG parts availability.
Got a CAYC problem? Ask for free.
Describe the symptoms — TorqFix replies with a diagnosis cited from verified workshop data.
Get free diagnosis →Who makes these pages, and how
TorqFix was built by a mechanic — after a 2,700 km drive with five roadside repairs that no diagnostic tool could explain.
The figures on this page come from manufacturer workshop documentation and are shown as they are. The page is assembled automatically from that data — it is not written by an AI. The AI works in the chat, where it answers for your specific car. It writes nothing here.
Variants of the same model differ. Cross-check torque against the factory manual for your engine before final tightening.
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The story behind TorqFix →Workshop data on this page last updated 22 Aug 2026.