2009 Candy White Caddy

[Klein]

As for today I thought I’d fit the autolight kit I bought a little while ago. Quite easy to do, pop the old switch out, plug in the sensor and then plug that into the new light switch. I ran the wire down the side of the dash and stuck it at the bottom of the windscreen, done!



Since the weather was still nice thought I’d do the rear wiper delete, everything was straight forward but decided to make life harder for myself and try to get the seal and nut fitted on the back of it so took an extra half an hour!

nice mod

what was the cost?

[Hutchysrs50]

Yeah, it gives another nice touch to the interior.

It was around £50 for the kit and was all direct fit.

[Hutchysrs50]

As usual, a million things going on, literally somthing happening everyday. For this update I’ll keep it engine and service related’ish.

I’m getting some important electrical work done which means the vans off the road for a few days.... so what better opportunity than to rebuild the engine.

To recap it’s a 2009 prefacelift Caddy with the nice and strong 2.0 SDI engine, having covered 72,000 miles.

Weak points - injectors, injector seals & camshafts.


First up, picture of what’s ahead.




So prior to the work I tested the injectors and got a replacement for the most worn one then stripped down and cleaned the other 3 and fitted all new gaskets, seals and bolts to them all.
Also cleaning the cylinder head where the injectors sit to avoid future trouble.

I went for the FAI seal kits as they are a well known “oem quality” brand.



Started stripping the engine down removing everything back to a bare cylinder head, cleaned the inlet manifold and replaced the gasket with a new one,
Cleaning the EGR valve and throttle body/ASV with brake cleaner and cleaning the map senor and air flow meter with electrical contact cleaner.

Fuel pump was removed so I could clean the head up better and replace the gasket with one from TPS since it’s been leaking since I purchased the van.

Stripped down


New camshaft etc in place


The old camshaft was worn in a few places and tappets had seen better days but perfectly serviceable really. Nice new camshaft with updated black top double spring tappets and all new bolts, it’s going to be like a brand new engine!

I got 4 new Bosch glow plugs, Bosch oil filter and Bosch fuel filter so I know they’ll all be up to scratch and decided to go for a direct fit cone in a box K&N filter for that extra 0.5bhp gain

[Hutchysrs50]

So not many more pictures of the engine work but it’s all back together and running nicely now. Next bit might be a little boring for some of you so you might want to skip down abit but this is a dairy to keep track so not all fancy pictures

Wish I had a dyno to check before and after results but that’s not a luxury I have.

So the boring bit..

- Fuel tandom pump has been leaking since I got the van. It was removed, stripped down, cleaned and refitted with a new genuine gasket from VW.

- The oil filter housing has been leaking since I got the van also. I removed the full housing to clean everything properly and refitted with a new genuine gasket from VW. I also fitted a new Bosch filter and o-ring seal since to my amazement there was no seal fitted previously! No wonder it was leaking

- An odd injector had been fitted in the past, I noticed when I took the rocker cover off to inspect the camshaft.... So a replacement was sourced from a 2010 caddy with 40,000 miles so a good low mileage unit. I removed all 4 injectors and cleaned the nozzles on them all then refitted with brand new FAI seal kits and new stretch bolts. New injector tops were fitted so had to be set up properly with the new lash setting of 180° which should aid performance / MPG / engine running etc

- The inlet manifold and throttle body (ASV) were removed and cleaned, then refitted with new FAI gaskets.

- The MAP sensor and air flow meter were removed and gently cleaned with electrical contact cleaner and a soft brush attachment on the tin.

- The timing belt was removed and inspect but is a new INA belt, water pump is also new.

- The Camshaft was looking worn and almost damaged in a few places. The tappets were worn and showing some age but still serviceable, same story with the bearings. The camshaft was replaced with a new forged unit. The tappets replaced with new uprated black top double spring INA units and bearings supplied by FAI with new camshaft oil seal and all new stetch bolts, some from FAI and some from VW.

[Hutchysrs50]

So with the top end rebuilt completed a service was needed. Done a few miles after following the bed in procedure of the camshaft, took it for a long run to get the oil nice and hot, jacked it up and removed the sump plug.

Left the oil dripping out and replaced the air filter with a K&N unit. Really nice piece of kit and a perfect fit.



Oil filter and fuel filters both replaced with new Bosch filters with any new gaskets and seals used.



Shiney new sump plug fitted and torqued correctly then topped up with VW longlife oil

[Hutchysrs50]

Bit of a nicer update, facelift highline cluster coded and fitted! one of the best upgrades yet and compliments the rest of the interior work I’ve done so well.

Side by side. Lowline poverty spec pre-facelift dashboard with blank top half and not even a temperature gauge next to a top spec facelift highline cluster.



Which of course needs a wiring harness to make it plug in and work since the connectors are totally different. Made my own loom soldering each contact to a replacement pin then heat shrink into place to keep them secure and stop shorting out. once tested I filled the plug with sealant to stop anything rubbing in the future.



And of course fitted


I’ll add more pictures soon as I’ve got a few other interior pieces I’ve fitted so will clean the inside and get a few snaps

[brooneye]

Looks good pal


Sent from my iPhone using Tapatalk

[Barbel330]

Good skills mate, really nice work.

[Caddy63-Adrian]

Loving the caddy! Do you have a link to where the auto light kit was from, there’s so many different ones on eBay!

[Liam]

great work so far pal

[Hutchysrs50]

So seems the top end rebuild didn’t solve my slight misfire / judder on idle. Vans been to a few specialists and nobody knows what it is, injectors all performing fine, every sensor checked or replaced.

Only thing we all agree on is cylinder 1 has the issue. Cylinder one has damage around the tappets from somthing previously....

Cylinder 1 glow plug black, others nice and new.



And then a picture of the damage around cylinder 1 tappet. Note the marks on the back wall/lip of the cylinder head also? No idea what’s caused this or what’s happened in the past.



and also cylinder 1 had the odd injector fitted from a 1.9 TDI so we think somthing has failed and damaged the head. Which means one thing... major rebuild now!

Start things off.
Got a good low mileage second hand cylinder head. Had done around 60,000 with proof so was pleased with that, injector bores all fine so good to go



Which then got stripped down to this...

Everything removed back to a bare head. Valves all removed then the head cleaned so it’s spotless, no carbon build up or dirt in the ports. valve guides inspected / repaced if needed. Valve stem oil seals replaced with new ones & valve seats reground in for longer that usual for mega compression.... and of course a very light lick over skim mainly to remove any dirt or parts of the old gasket and to make sure it’s 100% flat and smooth.

Once that works done I can move onto fitting the new camshaft, bearings tappets and other new things but I’ll update with that at the time.

Bottom end will be getting a full check over also. Checking and cleaning the bores if needed and the pistons getting a really good clean up.

[Liam]

that old head looks well past its best

[Hutchysrs50]

that old head looks well past its best

Indeed, I should have replaced it when I had it stripped down but I knew it had a bad injector I was replacing so didn’t think much of it, more fool me I suppose.

Another update coming.

[Hutchysrs50]

A little update regarding the mk5 golf multifunction steering wheel i fitted.
Long battle it’s been but since fitting the newer facelift clocks it’s been a great upgrade to have. Downside is it didn’t work with the RCD330 plus headunit I fitted... until my adaptor harness came



Hard to show I suppose but here’s a screenshot of a video I took showing the volume adjusting properly from the wheel.



And to top it all off, now I know it’s all working I’m getting the steering wheel, leather handbrake and leather gear selector gator retrimmed with fresh leather & red stitching to match the red seat belts.

[Liam]

fancy doing a total review of that rcd330 unit as a seperate post ? hard to get a full decent write up from a caddy owner