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Condition Value
expand_moreAir intake system
Induction-pipe flap control unit 7.38 lbf⋅ft
expand_moreIntake manifold
All Volkswagen gasoline straight-4 1.6 Liters BGU engines 18.44 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSE engines 18.44 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSF engines 18.44 lbf⋅ft
At the cylinder head 14.75 lbf⋅ft
Upper section of intake manifold 5.9 lbf⋅ft
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 14.75 lbf⋅ft
All other modifications 16.23 lbf⋅ft
expand_moreAuxiliary assemblies
Auxiliary drive belt deflection pulley 36.88 lbf⋅ft
expand_moreAuxiliary drive belt tensioner
All Volkswagen diesel straight-4 2.0 Liters BDJ engines 14.75 lbf⋅ft
expand_moreM8
First stage 14.75 lbf⋅ft
Second stage 90°
M10 33.19 lbf⋅ft
All other modifications 18.44 lbf⋅ft
Air-conditioning compressor 18.44 lbf⋅ft
expand_moreAir-conditioning compressor bracket
All other modifications 33.19 lbf⋅ft
expand_moreAlternator
All Volkswagen gasoline straight-4 1.6 Liters BGU engines 16.96 lbf⋅ft
All Volkswagen diesel straight-4 1.9 Liters BJB engines 18.44 lbf⋅ft
All Volkswagen diesel straight-4 1.9 Liters BLS engines 18.44 lbf⋅ft
All Volkswagen diesel straight-4 2.0 Liters BMM engines 18.44 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSE engines 16.96 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSF engines 16.96 lbf⋅ft
All Volkswagen diesel straight-4 1.9 Liters BSU engines 18.44 lbf⋅ft
All other modifications 14.75 lbf⋅ft
expand_moreGenerator bracket
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 29.5 lbf⋅ft
All other modifications 33.19 lbf⋅ft
expand_moreVacuum pump
expand_moreScrews
Bottom 7.38 lbf⋅ft
Top 14.75 lbf⋅ft
expand_moreCarburetion
Exhaust gas return cooler 16.23 lbf⋅ft
expand_moreExhaust recirculation pipe
All Volkswagen diesel straight-4 1.9 Liters BJB engines 16.23 lbf⋅ft
Sealing rings must be replaced.
All Volkswagen diesel straight-4 1.9 Liters BLS engines 16.23 lbf⋅ft
Sealing rings must be replaced.
Nuts 18.44 lbf⋅ft
Seals and nuts must be replaced.
Screws 16.23 lbf⋅ft
Sealing rings must be replaced.
All Volkswagen diesel straight-4 1.9 Liters BSU engines 16.23 lbf⋅ft
Sealing rings must be replaced.
Fuel-distributing pipe 5.9 lbf⋅ft
expand_moreInjection nozzle (injector)
First stage 8.85 lbf⋅ft
Screws must be replaced.
Second stage 270°
expand_moreCharging
expand_moreCharge air pipes
2.0 TDI with diesel straight-4 2.0 L 138 HP at 4000 RPM, 320 N⋅m at 1750 RPM engine (2007.9–2010.8) 5.9 lbf⋅ft
expand_moreTurbocharger bracket
At the turbocharger 14.75 lbf⋅ft
On the engine block 29.5 lbf⋅ft
expand_moreTurbocharger oil feed line
Union nuts 16.23 lbf⋅ft
Support 7.38 lbf⋅ft
expand_moreTurbocharger oil return line
expand_moreAt the turbocharger
Support 18.44 lbf⋅ft
Otherwise 11.06 lbf⋅ft
Sealing rings must be replaced.
expand_moreOn the engine block
Banjo screws 44.25 lbf⋅ft
Sealing rings must be replaced.
expand_moreUnion nuts
All Volkswagen diesel straight-4 1.9 Liters BJB engines 22.13 lbf⋅ft
expand_moreCooling system
expand_moreCoolant pump
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 14.75 lbf⋅ft
All other modifications 11.06 lbf⋅ft
expand_moreCylinder head
expand_moreCamshaft bearing
All Volkswagen gasoline straight-4 1.6 Liters BGU engines 16.96 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSE engines 16.96 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSF engines 16.96 lbf⋅ft
All Volkswagen CNG straight-4 2.0 Liters BSX engines 14.75 lbf⋅ft
expand_moreAll other modifications
First stage 5.9 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreCylinder head screws
Figure 1. Cylinder head, Cylinder head screws, Volkswagen gasoline straight-4 1.6 Liters BGU.
Figure 1. Cylinder head, Cylinder head screws, Volkswagen gasoline straight-4 1.6 Liters BGU.
First stage 29.5 lbf⋅ft
Screws must be replaced. See figure 1.
Second stage 90°
Third stage 90°
First stage 29.5 lbf⋅ft
Screws must be replaced. See figure 1.
Second stage 90°
Third stage 90°
First stage 22.13 lbf⋅ft
Screws must be replaced. See figure 1.
Second stage 90°
Third stage 90°
expand_moreAll other modifications
First stage 25.81 lbf⋅ft
Screws must be replaced. See figure 1.
Second stage 44.25 lbf⋅ft
Third stage 90°
Fourth stage 90°
expand_moreRocker bridge
First stage 14.75 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreValve cover
All Volkswagen gasoline straight-4 1.6 Liters BGU engines 6.64 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSE engines 6.64 lbf⋅ft
All Volkswagen gasoline straight-4 1.6 Liters BSF engines 6.64 lbf⋅ft
expand_moreAt the cylinder head
expand_moreBearing casing
First stage 7.38 lbf⋅ft
Tighten new screws in inside-to-outside order.
Second stage 90°
All other modifications 7.38 lbf⋅ft
Valve play adjusting screw lock nuts 22.13 lbf⋅ft
expand_moreEngine block
expand_moreConnecting rod bearing
expand_moreM7
First stage 14.75 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreM8
First stage 22.13 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreAll other modifications
First stage 22.13 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreCrankshaft central screws
First stage 66.38 lbf⋅ft
Screws must be replaced.
Second stage 90°
First stage 66.38 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreWith threaded screw head
Figure 2. Engine block, Crankshaft central screws, Volkswagen gasoline straight-4 1.4 Liters BUD, With threaded screw head.
Figure 2. Engine block, Crankshaft central screws, Volkswagen gasoline straight-4 1.4 Liters BUD, With threaded screw head.
First stage 110.63 lbf⋅ft
Use new screw. See figure 2.
Second stage 180°
expand_moreOtherwise
Figure 3. Engine block, Crankshaft central screws, Volkswagen gasoline straight-4 1.4 Liters BUD, Otherwise.
Figure 3. Engine block, Crankshaft central screws, Volkswagen gasoline straight-4 1.4 Liters BUD, Otherwise.
First stage 66.38 lbf⋅ft
Use new screw. See figure 3.
Second stage 90°
expand_moreAll other modifications
First stage 88.51 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreFlywheel
First stage 44.25 lbf⋅ft
Screws must be replaced.
Second stage 90°
Flywheel cover 7.38 lbf⋅ft
expand_moreMain bearing
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 90°
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreAll other modifications
First stage 47.94 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreVibration damper
expand_moreAll other modifications
First stage 7.38 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreEngine control
Camshaft drive belt deflection pulley 14.75 lbf⋅ft
expand_moreCamshaft timing gear
Central screws 73.76 lbf⋅ft
Otherwise 18.44 lbf⋅ft
Central screws 73.76 lbf⋅ft
Wheel 18.44 lbf⋅ft
Central screws 73.76 lbf⋅ft
Otherwise 18.44 lbf⋅ft
Central screws 73.76 lbf⋅ft
Wheel 18.44 lbf⋅ft
First stage 14.75 lbf⋅ft
Screws must be replaced.
Second stage 90°
All other modifications 73.76 lbf⋅ft
Coupling drive tensioning roller 14.75 lbf⋅ft
Drive belt tensioner device 16.96 lbf⋅ft
Oil pump drive chain tensioner 11.06 lbf⋅ft
Timing case cover 7.38 lbf⋅ft
Toothed belt guard 7.38 lbf⋅ft
Toothed belt guard 7.38 lbf⋅ft
Use screw-locking compound.
expand_moreToothed belt tensioning roller
First stage 14.75 lbf⋅ft
Second stage 45°
First stage 14.75 lbf⋅ft
Second stage 45°
First stage 14.75 lbf⋅ft
Second stage 45°
First stage 14.75 lbf⋅ft
Second stage 45°
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 14.75 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreEngine lubrication
expand_moreOil cooler
Heat-exchanger on oil filter housing 18.44 lbf⋅ft
Oil drain plug 22.13 lbf⋅ft
Screws must be replaced.
expand_moreOil filter housing
Oil filter cover 18.44 lbf⋅ft
expand_moreOn the engine block
First stage 11.06 lbf⋅ft
Screws must be replaced.
Second stage 90°
Oil pump 11.06 lbf⋅ft
expand_moreOil pump chain wheel
First stage 14.75 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreOil sump
At the gearbox 18.44 lbf⋅ft
On the engine block 11.06 lbf⋅ft
expand_moreAll other modifications
At the gearbox 33.19 lbf⋅ft
On the engine block 11.06 lbf⋅ft
expand_moreEngine management
Camshaft sensor 7.38 lbf⋅ft
Exhaust gas temperature sensor 33.19 lbf⋅ft
Use hot screw paste
Glow plugs 11.06 lbf⋅ft
Knock sensor 14.75 lbf⋅ft
expand_moreLambda sensor
All Volkswagen diesel straight-4 1.9 Liters BJB engines 36.88 lbf⋅ft
Use hot screw paste
All Volkswagen diesel straight-4 1.9 Liters BLS engines 36.88 lbf⋅ft
Use hot screw paste
All Volkswagen diesel straight-4 2.0 Liters BMM engines 36.88 lbf⋅ft
Use hot screw paste
All Volkswagen diesel straight-4 1.9 Liters BSU engines 36.88 lbf⋅ft
Use hot screw paste
All other modifications 40.57 lbf⋅ft
expand_moreEngine mounting
expand_moreEngine bracket
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 180°
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 180°
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 180°
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 180°
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 36.88 lbf⋅ft
Screws must be replaced.
All other modifications 33.19 lbf⋅ft
expand_moreEngine mounting
expand_moreAt the bracket
First stage 14.75 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreOn chassis
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreOn engine bracket
First stage 44.25 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreSubframe
expand_moreOn chassis
First stage 51.63 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreTorque arm
expand_moreAt the subframe
First stage 73.76 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreAt the gearbox
First stage 29.5 lbf⋅ft
Screws must be replaced.
Second stage 90°
expand_moreExhaust system
expand_moreCatalytic converter
All Volkswagen diesel straight-4 1.9 Liters BJB engines 5.16 lbf⋅ft
All Volkswagen diesel straight-4 1.9 Liters BSU engines 5.16 lbf⋅ft
All Volkswagen CNG straight-4 2.0 Liters BSX engines 29.5 lbf⋅ft
Nuts must be replaced.
All other modifications 18.44 lbf⋅ft
Nuts must be replaced.
Catalytic converter bracket 29.5 lbf⋅ft
expand_moreDiesel particulate filter
At the turbocharger 5.16 lbf⋅ft
Parts must be replaced.
Differential pressure sensor lines 33.19 lbf⋅ft
Exhaust manifold 18.44 lbf⋅ft
Nuts must be replaced.
expand_moreExhaust manifold heat shields
All Volkswagen diesel straight-4 1.9 Liters BJB engines 14.75 lbf⋅ft
Nuts must be replaced.
All Volkswagen diesel straight-4 1.9 Liters BLS engines 18.44 lbf⋅ft
Nuts must be replaced.
All Volkswagen diesel straight-4 2.0 Liters BMM engines 18.44 lbf⋅ft
Nuts must be replaced.
expand_moreExhaust pipe
All Volkswagen diesel straight-4 2.0 Liters BDJ engines 16.96 lbf⋅ft
All Volkswagen diesel straight-4 2.0 Liters BST engines 16.96 lbf⋅ft
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 29.5 lbf⋅ft
Exhaust pipe bracket 18.44 lbf⋅ft
Particle filter bracket 16.96 lbf⋅ft
expand_moreIgnition system
expand_moreSpark plugs
All Volkswagen gasoline straight-4 1.4 Liters BUD engines 22.13 lbf⋅ft
All other modifications 18.44 lbf⋅ft
expand_moreStart system
expand_moreStarter
M10 44.25 lbf⋅ft
M12 55.32 lbf⋅ft

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2009 Volkswagen Caddy Box user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Volkswagen warranty policy for your region. In some regions DIY service may invalidate your warranty.

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Volkswagen Caddy Box service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2009 Volkswagen Caddy Box you're not only saving money, but also also improving your technical skills and learning something new.

Units:
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