Installing engine - vehicles with four-wheel drive: Audi 1.9 TDI (BJB, BLS, BSU)

🧭 Before you start

Fits: VW Caddy III (2K, 2004–2015)

• Opens: brake fluid, clutch fluid
• Renewed: if necessary

🔧 Engine codes this applies to

📋 Procedure

1. ⚠ When doing any repair work, especially in the engine compartment, pay attention to the following due to the cramped conditions:Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant and refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.Ensure that there is sufficient clearance to all moving or hot components. — Check clutch release bearing for wear and renew if necessary.
2. Clean splines of input shaft and lightly grease them with grease for clutch plate splinesElectronic Parts Catalogue.
3. Check whether dowel sleeves for centring engine/gearbox are fitted in cylinder block and install if necessary.
4. Rock engine to align engine mountings stress-free. If necessary, also loosen engine mountings on body.
5. Bolt left drive shaft to gearbox Running gear, axles, steering40Drive shafts; Removing and installing drive shaft.

6. Install front exhaust pipe with particulate filter .
7. Install air conditioner compressor Heating, air conditioning87Air conditioner compressor; Removing and installing air conditioner compressor.
8. Install power-assisted steering vane pump.
9. Install poly V-belt .
10. Push pipe/hose assembly (A) to stop into slave cylinder bleeder.
11. Push down clip (arrow).
12. Test line by tugging on it.
13. Remove hose clamp, up to 25 mm in diameter3094 from pipe/hose assembly.
14. Bleed clutch mechanism 30.
15. Install selector mechanism to gearbox 6-speed manual gearbox 02Q34Selector mechanism; Removing and installing selector mechanism.
16. Install noise insulation General body repairs, exterior50Body - front; Noise insulation.
17. Install engine control unit .
18. Install plenum chamber bulkhead General body repairs, exterior50Plenum chamber bulkhead.
19. With ignition switched off, connect battery earth strap Electrical system27Disconnecting and connecting battery.
20. Replenish coolant .
21. Carry out road test and read event memory afterwards .

Other AUDI procedures

• Checking cooling system for leaks
• Installing coolant pump – VW 1.9 TDI · 1 torque figures
• Installing thermostat – VW 1.9 TDI · 1 torque figures
• Checking engine oil cooler for leaks – VW Polo 6R
• Removing and installing anti-theft engine control unit (Golf)
• Removing and installing toothed belt – Audi · 56 torque figures
• Removing engine – Audi A8 D3 · 41 torque figures
• Removing camshaft timing chain from camshafts – Audi A6/A7 C7 · 38 torque figures
• Installing engine – Audi A8 D4 · 36 torque figures
• Removing and installing camshaft timing chain · 29 torque figures