Volkswagen CAAC Specifications
| Engine Model: Volkswagen CAAC |
| Engine Type: 4-cycle 4-cylinder DOHC 16-valve turbocharged liquid-cooled diesel |
| Total Displacement: 120.1 cu.in (1.96 L) |
| Rated Engine Power: 138 Hp (103 kW) at 3500 rpm |
| Fuel System Type: Common rail direct injection |
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The Volkswagen CAAC is a 2.0-liter turbocharged
inline-four diesel engine from the EA189 family, representing the mid-range
power offering within Volkswagen’s commercial vehicle diesel lineup. Produced
between 2009 and 2016, this powerplant was engineered specifically for the
Volkswagen Transporter T5 facelift and T6 generations, where it occupied the
"mid-high" power position. The CAAC became widely regarded as the optimal choice
within the Transporter range, delivering substantially more power than the 84 PS
and 102 PS base TDI variants while avoiding the complex reliability concerns
associated with the 180 PS Biturbo (CFCA) engine.
The EA189 family, to which the CAAC belongs, was Volkswagen’s workhorse diesel
architecture throughout the late 2000s and early 2010s. The CAAC utilizes a cast
iron cylinder block with a closed-deck design, providing the structural rigidity
required for turbocharged diesel operation. An aluminum alloy cylinder head
houses a double overhead camshaft (DOHC) valvetrain with 16 valves. The engine
employs a Bosch common rail direct injection system operating at pressures up to
180 MPa (1,800 bar), enabling precise fuel delivery across the operating range.
A variable geometry turbocharger (VGT) provides responsive boost delivery, with
peak torque of 340 Nm available from 1,750 rpm.
The CAAC was calibrated to deliver 103 kW (140 PS) and 340 Nm, a configuration
that prioritized durability and consistent torque delivery over peak power. This
engine, equipped with a Diesel Particulate Filter (DPF) and meeting Euro 5
emission standards, became the preferred powertrain for the Transporter,
Caravelle, California, and Multivan across European and other global markets.
Its reputation for reliability relative to higher-output variants of the EA189
family, combined with its tunability via simple software updates, established
the CAAC as a benchmark in the commercial vehicle segment.
The engine operates on a four-stroke diesel cycle with a variable geometry
turbocharger and intercooler providing forced induction. It is configured for
longitudinal or transverse installation depending on the vehicle platform,
primarily in front-engine, front-wheel-drive or all-wheel-drive configurations
within the Transporter range. Engine management is controlled by a Bosch ECU
utilizing a common rail direct injection system.
Engine Type: Inline-4, water-cooled, 4-stroke diesel, TDI, common rail
Displacement: 1,968 cc (120.1 cu.in)
Bore x Stroke: 81.0 mm x 95.5 mm (3.19 in x 3.76 in)
Compression Ratio: 16.5:1
Firing Order: 1-3-4-2
Idle Speed: 800 ± 50 rpm (in neutral)
Maximum Power: 103 kW (140 PS / 138 hp) @ 3,500 rpm
Maximum Torque: 340 Nm (251 lb-ft) @ 1,750-2,500 rpm
Maximum Engine Speed: 5,000 rpm (governed)
Turbocharger: Variable geometry turbocharger (VGT)
Maximum Boost Pressure: 1.6-1.8 bar (23-26 psi) relative pressure
The cylinder block is constructed from cast iron with a
closed-deck design, providing exceptional structural rigidity to withstand the
high cylinder pressures of turbocharged diesel combustion. The block
incorporates five main bearings supporting the crankshaft. Reinforced bulkheads
and thick cylinder walls contribute to durability under sustained high-load
commercial vehicle operation. Cylinder Bore Diameter: 81.0 mm (3.19 in). Main
Bearing Journal Diameter: 58.0 mm (2.28 in).
Piston Material: High-temperature aluminum alloy with a re-entrant combustion
bowl in the crown. Piston Cooling: Oil jets are mounted in the cylinder block to
direct a continuous spray of engine oil to the underside of each piston crown.
Crankshaft: Forged steel, fully counter-weighted. Connecting Rods: Forged steel,
fracture-split construction for precise cap alignment. Cylinder Block
Construction: Cast iron with closed-deck design.
The cylinder head is manufactured from aluminum alloy
and houses the DOHC valvetrain. The combustion chamber design incorporates a
centrally positioned injector with a multi-hole nozzle to optimize fuel spray
pattern and air-fuel mixing. The cylinder head integrates the exhaust manifold
in a compact configuration to minimize heat loss to the coolant. The valvetrain
utilizes hydraulic lash adjusters, eliminating manual valve clearance adjustment
requirements.
Valvetrain: DOHC, belt-driven, with 16 valves total. Hydraulic lash adjusters
maintain zero valve clearance automatically. Intake Valve Diameter: 32.0 mm
(1.26 in). Exhaust Valve Diameter: 28.0 mm (1.10 in). Valve Material: Hollow
stem construction in exhaust valves for improved heat dissipation. Valve Seat
Material: High-strength sintered alloy. Camshaft Drive: Toothed rubber timing
belt with automatic tensioner; belt also drives the water pump.
The fuel system utilizes a Bosch common rail direct
injection configuration. A high-pressure pump supplies fuel to a common
accumulator rail, from which solenoid-type injectors deliver precisely metered
fuel to each cylinder. The system supports multiple injection events per
combustion cycle, including pilot, main, and post-injections, enabling reduced
combustion noise and DPF regeneration capability.
Fuel Injectors: Solenoid-type injectors with multi-hole nozzles. High-Pressure
Pump: Single-piston or two-piston radial plunger pump driven by the camshaft.
Common Rail Pressure: 160-180 MPa (23,200-26,100 psi) maximum operating
pressure. Low-Pressure Fuel System Pressure: 400-600 kPa (58-87 psi).
Intake Manifold: Composite resin (plastic) construction with integrated charge
air temperature sensor and swirl control valves. Turbocharger: Variable geometry
turbocharger with intercooler mounted in the vehicle front end. Throttle Body:
Electronically controlled intake throttle valve for EGR management and engine
shut-down refinement. Fuel Requirement: Diesel fuel meeting EN 590 or equivalent
specifications, with minimum cetane rating of 51.
The lubrication system is a fully pressurized wet-sump
design incorporating a gear-type oil pump driven by the crankshaft. The system
is designed to accommodate the thermal and mechanical demands of turbocharged
diesel operation and includes a dedicated oil circuit for the turbocharger
bearing. Low-SAPS (Sulphated Ash, Phosphorus, Sulphur) oil meeting VW 507.00
specification is mandatory to protect the Diesel Particulate Filter.
Oil Pump Type: Gear-type pump.
Recommended Oil Viscosity: 5W-30 or 0W-30, meeting VW 507.00.
Oil Capacity (with filter change): 7.0 liters (7.4 qt).
Oil Capacity (without filter change): 6.5 liters (6.9 qt).
Oil Pressure (at 3,000 rpm, warm): 300-400 kPa (43.5-58.0 psi).
Oil Pan Material: Stamped steel with integrated baffling.
Oil Cooler: Plate-type oil-to-water heat exchanger mounted to the cylinder
block.
The cooling system is a pressurized design utilizing a
centrifugal water pump driven by the timing belt. The water pump is located on
the front of the engine and is replaced as part of the timing belt service. A
wax-type thermostat regulates coolant flow. The system incorporates a separate
cooling circuit for the EGR cooler. Coolant Type: Ethylene-glycol based
antifreeze, phosphate and silicate-free formulation, meeting G12++ or G13
specification.
Coolant Capacity (engine and radiator): 8.5-9.5 liters (9.0-10.0 qt).
Thermostat Opening Temperature: 82-88 °C (180-190 °F).
Radiator Cap Pressure: 90-110 kPa (13.1-16.0 psi).
Water Pump Type: Belt-driven centrifugal pump with mechanical seal.
Timing Drive: Toothed rubber timing belt with an
automatic spring-loaded tensioner. The belt drives the camshafts and the water
pump. The manufacturer-specified replacement interval is 210,000 km (130,000
miles), though shorter intervals (120,000 km / 75,000 miles or 5 years) are
recommended in commercial applications.
Accessory Drive: Single serpentine belt driving the alternator and air
conditioning compressor. An automatic spring-loaded tensioner maintains
consistent belt tension. Power steering is electrically driven on most
Transporter applications.
EGR (Exhaust Gas Recirculation): High-pressure EGR system with an EGR cooler and
electronically controlled valve. The EGR unit is located at the front of the
engine, offering improved service access compared to passenger car EA189
installations.
Emission Control System: Includes a close-coupled Diesel Oxidation Catalyst
(DOC), a Diesel Particulate Filter (DPF), upstream and downstream pressure
sensors, and a Positive Crankcase Ventilation (PCV) system. The engine complies
with Euro 5 emission standards.
Engine Management System: Bosch ECU with integrated boost pressure control, VGT
vane position control, EGR control, DPF regeneration management, and glow plug
control. The ECU utilizes MAP (Manifold Absolute Pressure), MAF (Mass Air Flow),
and exhaust gas temperature sensors.
Overall Length: 640 mm (25.2 in)
Overall Width: 680 mm (26.8 in)
Overall Height: 720 mm (28.3 in)
Dry Weight (complete engine): 155 kg (342 lb)
Engine Oil Change Interval: 15,000 km (9,000 miles) or
12 months under normal operating conditions. Commercial vehicle applications and
severe service (frequent short trips, heavy loads) require 10,000 km (6,000
mile) intervals. Engine Oil Filter Change Interval: With every oil change.
Coolant Replacement Interval: 120,000 km (75,000 miles) or 5 years. Drive Belt
Inspection: Every 10,000 km (6,000 miles) for cracks, fraying, glazing, and
proper tension. Air Filter Element: Replace every 40,000 km (25,000 miles); more
frequent replacement is required in dusty environments.
Timing Belt Replacement Interval: Officially 210,000 km (130,000 miles); a
reduced interval of 120,000 km (75,000 miles) or 5 years is recommended in
commercial applications or severe service. Glow Plug Replacement Interval: Glow
plugs are serviceable items with a recommended inspection every 100,000 km
(60,000 miles). Replacement is indicated by extended cranking times on cold
start or glow plug-related fault codes. Fuel Filter Replacement Interval: 30,000
km (18,000 miles) or 2 years.
The water separator should be drained periodically. DPF Maintenance: Diesel
Particulate Filter regeneration occurs automatically under normal driving
conditions. Frequent short trips preventing regeneration may require forced
regeneration service. Ash accumulation necessitates DPF cleaning or replacement
at extended intervals. EGR Valve Cleaning: The EGR valve and cooler may require
cleaning at intervals of 100,000-150,000 km (60,000-90,000 miles) if clogging
occurs, particularly in vehicles operated primarily on short trips or with
extended oil change intervals.
Cylinder Head Bolts, Step 1: 40 Nm (30 lb-ft)
Cylinder Head Bolts, Step 2: 80 Nm (59 lb-ft)
Main Bearing Cap Bolts: 30 Nm (22 lb-ft)
Connecting Rod Cap Bolts: 25 Nm (18 lb-ft)
Camshaft Bearing Cap Bolts: 14 Nm (10 lb-ft)
Intake Manifold Bolts: 20 Nm (15 lb-ft)
Exhaust Manifold Nuts: 25 Nm (18 lb-ft)
Turbocharger Mounting Nuts: 30 Nm (22 lb-ft)
Common Rail Mounting Bolts: 22 Nm (16 lb-ft)
High-Pressure Pump Mounting Bolts: 22 Nm (16 lb-ft)
Oil Pan Bolts: 12 Nm (9 lb-ft)
Valve Cover Bolts: 10 Nm (7 lb-ft)
Crankshaft Pulley Bolt: 200 Nm (148 lb-ft)
Flex Plate / Drive Plate Bolts: 120 Nm (89 lb-ft)
The Volkswagen CAAC engine was utilized extensively
across Volkswagen’s Transporter range, serving as the mid-high power diesel
option throughout the T5 facelift and T6 generations.
2010-2015 Volkswagen Transporter T5 (Facelift): The primary application for the
CAAC in the updated T5 range, where it replaced earlier 2.0 TDI variants. The
engine was offered in panel van, Kombi, and chassis cab configurations.
2015-2016 Volkswagen Transporter T6: Continued in the sixth-generation
Transporter, serving as the 140 PS TDI engine option before the transition to
EA288 family engines. The CAAC was available in all Transporter body styles
including panel van, Kombi, and chassis cab.
2010-2016 Volkswagen Caravelle: Installed in the Caravelle passenger van
variant, where the CAAC provided refined power delivery for passenger transport
applications.
2010-2016 Volkswagen California: Utilized in the California camper van, where
the engine’s combination of torque and fuel efficiency was well-suited to the
vehicle’s dual-purpose design.
2010-2016 Volkswagen Multivan: Applied in the Multivan premium passenger van,
offering a balance of performance and refinement for this higher-trim variant.
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