Volkswagen CJDA Workshop Manual
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Volkswagen CJDA Workshop Manual

Volkswagen CJDA Workshop Manual

Industrial engine
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Table of Contents

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Service
Workshop Manual
Industriemotoren - Industrial Engines
2009 ▶
Workshop Manual for Diesel Engine (2.0 l/
36-75 kW_EA 189)
Edition 05.2015
Engine code
Service Department. Technical Information
CJDA CJDD CPYA CPYB CPYC CPYD CPYE
3

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Summary of Contents for Volkswagen CJDA

  • Page 1 Service Workshop Manual Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/ 36-75 kW_EA 189) Edition 05.2015 Engine code CJDA CJDD CPYA CPYB CPYC CPYD CPYE Service Department. Technical Information...
  • Page 2 Service Repair Group overview for workshop manual Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) Edition 05.2015 When filing a Technical Bulletin, enter the bulletin number in the column adjacent to the Repair Group. When using the Maintenance Manual you can then see at a glance whether Technical Bul- letins have been published which refer to the Repair Group you are looking for.

  • Page 3: Table Of Contents

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Contents Technical data 00 - ..................Description of symbols .
  • Page 4 ............. . Measured value blocks, engine codes CJDA, CJDD .
  • Page 5 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Evaluating measured value blocks at idling speed ..........6.3.1 Display group 1 - Injected quantity .
  • Page 6 ............Assembly overview - toothed belt drive, engine codes CJDA, CJDD, without crankshaft seal .
  • Page 7 ........... . Assembly overview - cylinder head cover, engine codes CJDA, CJDD .
  • Page 8 ........Oil filter bracket, oil cooler and oil pressure switch, engine codes CJDA, CJDD .
  • Page 9 ....................Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE .
  • Page 10 ... . . 2.4.2 Checking control line to turbocharger, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE ..................
  • Page 11 1.6.1 Fuel system, engine codes CJDA, CJDD ............
  • Page 12 1.1.1 Engine codes CJDA, CJDD ..............
  • Page 13 ....... . 3.12 Regeneration of diesel particulate filter, engine codes CJDA, CJDD ......
  • Page 14 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve ............... 3.1.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit...
  • Page 15 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp 5 17 Current flow diagrams, engine codes CJDA, CJDD, compliant with emission standard (EU5) ....................
  • Page 16 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Contents...

  • Page 17: Technical Data

    ◆ The procedures described in this workshop manual must on- ly be carried out by personnel which has undergone the ap- propriate training conducted by Volkswagen. If you have not undergone the appropriate training or if you are not suffi- ciently qualified, have a qualified workshop perform any re- pair work.
  • Page 18 Volks- wagen. ◆ Please note that when using replacement parts and acces- sories which were not supplied by Volkswagen, the specified characteristics of the machine und thus the safety may be impaired. ◆ Before performing repair work on a vehicle/machine, make sure that all necessary tools and replacement parts are ready to hand.

  • Page 19: General Safety Notes

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 General safety notes WARNING Proceed with particular care when working on the vehi- cle/machine. Adhere to the general safety regulations as well as your good judgment. Never take the risk of being injured.
  • Page 20 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 WARNING During any repair work in the engine or engine compart- ment there is a risk of scalding, injuries, accidents and fire. Never start the engine of the vehicle/machine in small or enclosed spaces, which are not sufficiently ventilated.

  • Page 21: Technical Data

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 WARNING When working in the engine compartment of a vehicle/ machine using tools or with the engine running, always tie back long hair. Never wear a neck tie, a scarf, a neck lace, loose-fitting clothing, or similar.

  • Page 22: Engine Data

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 The engine number (“engine code” and “serial number”) can be found at the joint -arrow-. Additionally there is a sticker on the toothed belt guard with “en- gine code”...
  • Page 23 2.0 / 4 Output kW at rpm 44/2700 44/2700 Torque Nm at rpm 200/1750 200/1750 Bore Diame- 81.0 81.0 ter, mm Stroke 95.5 95.5 Weight (without attach- ments and diesel partic- ulate filter) Volkswagen Technical Site: http://vwts.ru http://vwts.info 3 Technical data...
  • Page 24 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Engine codes CPYE CPYF Compression ratio 16.5 16.5 Fuel min. Diesel in accordance with DIN EN Diesel in accordance with DIN 590 with min. 51 CN EN 590 with min.
  • Page 25 Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Engine codes CPYG Upper idling speed 3400 Lower idling speed 830 +50/-25 Euro 5 diesel engines Engine co- CJDA CJDD Manufactured 07.09 ► 11.10 ► Engine desig- TDI 2.0 - 475* NE TDI 2.0 - 475 NE nation...

  • Page 26: Service Work

    ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims. Note ◆ If you do not have the specialist skills required for the work described in this manual, we strongly recommend that you have the work performed exclusively in a qualified workshop.

  • Page 27: Service Intervals

    Note ◆ If the intended use of the Volkswagen industrial engine has not been evaluated by means of an engine parameter test, the operating conditions cannot be assessed properly by Volkswagen.

  • Page 28: Countries With High Sulphur Content In Diesel Fuel

    The service interval is applicable for the engines listed in this chapter starting from the point of commission- ing and delivery. Service intervals / events: CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE, CPYF, CPYG All engines Service type...

  • Page 29: Severe Operating Conditions

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Countries with high sulphur content in diesel fuel Bahrain Serbia, Montenegro, Voj- Macedonia Sri Lanka vodina, Kosovo Bangladesh Cambodia Moldova South Africa Chile Kazakhstan Mozambique Suriname Dominican Republic Kenya...

  • Page 30: Scope Of Interval Service

    ◆ In this case, the engine oil must be changed every 600 oper- ⇒  P age ating hours or after 1 year ◆ Volkswagen recommends to double the frequency of service ⇒  P age work according to the operating conditions 11, i.e.
  • Page 31 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Scopes of service Service type Scopes of service Page Engine code/PR No./ Remarks ⇒  P age 26 ◆ Interval service ◆ Vehicle self-diagnosis: read event memory of all systems ◆...

  • Page 32: Additional Work

    – Renew fuel filter CPYB ◆ Diesel conforming to EN CPYC CPYD CPYE ◆ Diesel not conforming to CPYF EN 590 CPYG CJDA CJDD ⇒  P age 454 CPYA – Perform service work on CPYB diesel particulate filter CPYC CPYD CPYE...

  • Page 33: Scopes Of Service For Gas Systems

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Every 4,800 operating hours Additional work Engine code Page ⇒  P age 284⇒  P age CJDA – Renew coolant CJDD – Renew coolant CPYA pump CPYB...

  • Page 34: Descriptions Of Work, Engine, General

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note The applicable service intervals for the gas system must be ob- tained from the manufacturer of the gas system. Descriptions of work, engine, general In this chapter you will find any scopes of service which cannot be assigned to one of the repair groups.

  • Page 35: Add-On Parts On The Engine Peripherals

    Repair work - important information Any repair work is performed by a workshop which is certified for servicing your Volkswagen industrial engine. For less com- plex repair work which can be performed with the engine instal- led, drive the vehicle to the workshop. If this is not possible, you can request a mechanic to provide assistance.
  • Page 36 Volkswagen Group for servicing the object of purchase. ◆ the object of purchase has been fitted with components which are not approved by the Volkswagen Group or the ob- ject of purchase has been modified in a way which has not been approved by the Volkswagen Group.
  • Page 37 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ the purchaser did not adhere to the regulations for handling, servicing and maintaining the object of purchase. 4 - Any regular wear and tear is exempt from the warranty. 5 - If the workshop to which the purchaser has asserted a claim is not able to take the remedies in due time, the purchaser shall be entitled to hold back any pending payments until the...

  • Page 38: Vehicle Self-Diagnosis

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 01 - Vehicle self-diagnosis Vehicle self-diagnosis Note The engine control unit -J623- must be coded when the engine is commissioned for the first time. ⇒  P age Features of vehicle self-diagnosis ⇒ ...

  • Page 39: Available Diagnosis Functions When Using The Vehicle Diagnosis, Testing And Information System

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 tronics” to display the control unit identification and the coding ⇒  P age Note Instead of the vehicle diagnosis, testing and information system other diagnosis systems, such as the DiagRA, may be used as well.

  • Page 40: Connecting Test Box To Check Lines

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● All electrical consumers must be switched off. ● Earth connections OK Procedure – Connect connector of diagnostic cable -VAS 5051B/1- or re- mote head to diagnostic connection. –...

  • Page 41: Connecting Test Box -V.a.g 1598/42- Using Adapter Cable -V.a.g 1598/39-1

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Connect test box -V.A.G 1598/42- using: ◆ adapter cable -V.A.G 1598/39-1- ⇒  P age 25, or ◆ adapter cable -V.A.G 1598/39-2- ⇒  P age 1.4.1 Connecting test box -V.A.G 1598/42- using adapter cable -V.A.G 1598/39-1- Special tools and workshop equipment required ◆...

  • Page 42: Connecting Test Box -V.a.g 1598/42- Using Adapter Cable -V.a.g 1598/39-2

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.4.2 Connecting test box -V.A.G 1598/42- using adapter cable -V.A.G 1598/39-2- Special tools and workshop equipment required ◆ Test box -V.A.G 1598/42- ◆ Adapter cable -V.A.G 1598/39-2- Prerequisites ●...

  • Page 43: Clearing Event Memory

    If a fault cannot be cleared, seek advice from an authorised dealership or from an employee who has been trained accord- ingly by Volkswagen. Static faults If one or more static faults are stored in the event memory, it is recommended in agreement with the customer to rectify these faults using "Guided fault finding".

  • Page 44: List Of Fault Codes

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note After eliminating faults the event memory must be read again as follows and then cleared. – Start engine and run at idling speed. – Connect vehicle diagnostic tester, and select engine control ⇒ ...
  • Page 45 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ 00280 = Fault code ◆ P0118 = Additional fault code ◆ Coolant temperature sender -G62- = faulty current path or fault location ◆ Signal too high = Fault type as text ◆...

  • Page 46: Fault Code: 00022/P0016

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Fault code: 00022/P0016...00146/P0092 Indicated on display Possible cause of fault Possible effects Fault remedy 00022/P0016 Bank 1, camshaft posi- tion sender-G40 /crank- shaft position sender- ⇒ ...
  • Page 47 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 00072/P0048 Charge pressure control valve, bank 1/charger1 Short to positive – Check electrical con- ◆...
  • Page 48 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Too high – Checking fill level of ◆ Fuel level too low ◆ Glow period warning fuel tank lamp -K29- lights up ◆...
  • Page 49 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault – Check fuel metering ◆ Open circuit or line ◆ Failure of metering valve -N290- short-circuit unit...

  • Page 50: Fault Code: 00257/P0101

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Fault code: 00257/P0101...01687/P0697 Indicated on display Possible cause of fault Possible effects Fault remedy 00257/P0101 Air mass meter -G70- Implausible signal – -G70- Check. ◆ Open circuit or line ◆...
  • Page 51 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy No signal – -G70- Check. ◆ Open circuit or line ◆ EGR is switched off. ⇒ ...
  • Page 52 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 00275/P0113 Intake air temperature sender -G42- Signal too large – -G42- Check. ◆ Wire open circuit or ◆...
  • Page 53 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy ⇒  Implausible signal – -G62- Check. ◆ Open circuit or line ◆ No limitation “Checking coolant short-circuit temperature sender...
  • Page 54 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Signal too large – -G62- Check. ◆ Wire open circuit or ◆ Alternative values are ⇒ ...
  • Page 55 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Signal too high – Check -J338- ◆ Wire open circuit or ◆ Regeneration is ⇒ ...
  • Page 56 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault – -Z19- Check. ◆ Wiring open circuit ◆ If there is a definite ⇒ ...
  • Page 57 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy ⇒  Implausible signal – -G81- Check. ◆ Open circuit or line ◆ No limitation “Checking fuel tem- short-circuit perature sender...
  • Page 58 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 00402/P0192 Fuel pressure sender -G247- Short to earth – -G247- Check. ◆ Wire open circuit or ◆...
  • Page 59 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electr. fault in circuit – -N33- Check. ◆ Open circuit or line ◆ Engine is switched off ⇒ ...
  • Page 60 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Signal too large – -G31- Check. ◆ Open circuit or line ◆ Torque limiting; regen- ⇒ ...
  • Page 61 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 00614/P0266 – Check injector deliv- ◆ Adaption values do ◆ Glow period warning Incorrect injection quanti- ery calibration values/ not match adaption lamp -K29- lights up...
  • Page 62 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 00626/P0272 – Check injector deliv- ◆ Adaption values do ◆ Incorrect injection Incorrect injection quanti- ery calibration values/ not match adaption quantity.
  • Page 63 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 00779/P0302 – Checking compres- ◆ Poor compression ◆ Slightly irregular en- Misfiring detected in cyl. ⇒ ...
  • Page 64 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy No signal – -G28- Check. ◆ Open circuit or line ◆ Limp mode via cam- ⇒ ...
  • Page 65 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Short to earth – Check -J179- ◆ Wire open circuit or ◆ Glow plug control ⇒ ...
  • Page 66 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Malfunction – Check -N18- ◆ -N18- defective ◆ Glow period warning ⇒  P age 89, final lamp -K29- lights up control diagnosis...
  • Page 67 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Signal too large – Check -G212- ◆ Wire open circuit or ◆ Particulate filter re- ⇒ ...
  • Page 68 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Low performance – Check -G212- ◆ Diesel oxidising cata- ◆ Difference between ⇒  P age 437, check lytic converter clog- exhaust gas tempera-...
  • Page 69 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Implausible signal – Check components for ◆ Open circuit or line ◆ None working speed control short-circuit ⇒ ...
  • Page 70 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Short to earth – -G235- Check. ◆ Wiring short to earth ◆ Torque limiting; diesel ⇒ ...
  • Page 71 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 01542/P0606 ◆ Internal defect in en- ◆ None Control unit defective gine control unit -J623- 01542/P0606 –...
  • Page 72 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Short to positive – Pull off relay, and read ◆ Wiring open circuit or ◆...
  • Page 73 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – Check electrical con- ◆ Open circuit or line ◆ Faults for sensors nection or sensor: short-circuit connected to this...
  • Page 74 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 01612/P064C – Check -J179- ◆ Wire open circuit or ◆ Glow period warning Glow period control unit ⇒ ...
  • Page 75 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – Check electrical con- ◆ Open circuit or line ◆ Limp mode nection or sensor: fuel short-circuit pressure sender;...
  • Page 76 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Short to earth – Check wiring to auto- ◆ Wire open circuit or ◆ One of the glow plugs matic glow period con- wire has short to is not functional...
  • Page 77 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault in current – Check -J179- ◆ Open circuit or line ◆ Glow plug control circuit ⇒ ...
  • Page 78 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault in current – Electrical test of glow ◆ Open circuit or line ◆...
  • Page 79 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Implausible signal – Check -J179- ◆ Open circuit or line ◆ Entire glow plug sys- ⇒ ...

  • Page 80: Fault Code: 04110/P100E

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Fault code: 04110/P100E...05779/P1693 Indicated on display Possible cause of fault Possible effects Fault remedy 04110/P100E Torque reduction to pro- tect turbocharger – -Ladedruckregelung- ◆ Charge pressure con- ◆...
  • Page 81 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – Check wires on injec- ◆ Open circuit or line ◆ Irregular idling or en- tor 3 (high and low) for short-circuit gine stalls...
  • Page 82 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault in current – Check -N18- ◆ Open circuit or line ◆ No regeneration of circuit ⇒ ...
  • Page 83 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – Check -N18- ◆ Open circuit in wire ⇒  P age 89, final ◆...
  • Page 84 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 05522/P1592 Altitude sender/charge pressure sender signal Implausible ratio – -G31- Check. ◆ Defective charge ◆...
  • Page 85 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 05655/P1617 Glow period warning lamp -K29- Open circuit/short to – Check -K29- ◆ Wire open circuit or earth ⇒ ...

  • Page 86: Fault Code: 08320/P2080

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Fault code: 08320/P2080 ... 11179 ... P2BAB Indicated on display Possible cause of fault Possible effects Fault remedy 08320/P2080 Exhaust gas temperature sender 1 Implausible signal –...
  • Page 87 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 08465/P2111 Throttle valve module Jammed in open position – Check -J338- ◆ -J388- soiled ◆...
  • Page 88 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 08488/P2128 Accelerator pedal posi- tion sender 2 Signal too large – Electrical test: con- ◆...
  • Page 89 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 08597/P2195 Lambda probe 1 - bank 1 Signal too lean – -G39- Check. ◆ Wiring open circuit ◆...
  • Page 90 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – -G39- Check. ◆ Wiring open circuit ◆ Zero quantity calibra- ⇒  P age 439 tion locked ◆...
  • Page 91 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – -G39- Check. ◆ Wiring open circuit ◆ Zero quantity calibra- ⇒  P age 439 tion locked ◆...
  • Page 92 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – -G39- Check. ◆ Wiring open circuit ◆ Zero quantity calibra- ⇒  P age 439 tion locked ◆...
  • Page 93 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Open circuit – -N276- Check. ◆ Open circuit in wire ◆ Failure of pressure ⇒ ...
  • Page 94 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault – -G495- Check. ◆ Open circuit or line ◆ Regeneration of die- ⇒ ...
  • Page 95 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Short to earth – -G495- Check. ◆ Wiring short to earth ◆ Regeneration of die- ⇒ ...
  • Page 96 ◆ -G450- defective bly overview - diesel ◆ Control lines between particulate filter -G450- and diesel – Check diesel particu- particulate filter clog- late filter, CJDA, ged or interchanged ⇒  P age CJDD 460, – Check diesel particu- late filter, CPYA, CPYB, CPYC, CPYD, ⇒ ...
  • Page 97 – Check control lines ⇒  P age 427, Assem- bly overview - diesel particulate filter – Check diesel particu- late filter, CJDA, ⇒  P age CJDD 460, – Check diesel particu- late filter, CPYA, CPYB, CPYC, CPYD, ⇒  P age...
  • Page 98 ⇒  “ Checking late filter ter overloaded, e.g. ◆ Regeneration of die- diesel particulate filter, due to excessive sel particulate filter engine codes CJDA, short-distance driving locked CJDD” on page 460, ◆ The load detection ◆ As of a soot loading of –...
  • Page 99 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Electrical fault – -G648- Check. ◆ Open circuit or line ◆ Regeneration of die- ⇒ ...
  • Page 100 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 0938/P247A Exhaust gas temperature sender 3, bank 1 Exhaust gas temperature – Primarily: electrical ◆...
  • Page 101 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy Signal too low – -G581- Check. ◆ Open circuit or short- ◆ Limp mode ⇒ ...
  • Page 102 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy – Check warning lamp ◆ Open circuit or short- ⇒  P age 89, final circuit in line control diagnosis ◆...

  • Page 103: Fault Code: 13256/P33C8

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 09780/P2634 Electric fuel pump 2 relay -J49- Short to positive – Check -J49- ◆ Wire has short to ◆...

  • Page 104: Fault Code: 49153/U0001

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Fault remedy 13257/P33C9 Soot loading of diesel particulate filter Soot threshold 2 excee- ◆ Diesel particulate fil- ◆ This fault path is used ◆...

  • Page 105: Final Control Diagnosis

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display Possible cause of fault Possible effects Fault remedy 54282/U140A Terminal 30 Open circuit – Check voltage supply ◆ Voltage supply too ◆ Engine will not start for engine control unit small ◆...
  • Page 106 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Procedure – Connect vehicle diagnostic tester, and select engine control ⇒  P age 23 unit. – Select diagnosis function “03-Final control diagnosis”. En- gine must be idling. Activating exhaust gas recirculation valve -N18- Note After the diagnosis function “03-Final control diagnosis”...
  • Page 107 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Activating alternator shutdown function (if present) – Press button. → The alternator is activated. ● The alternator warning lamp must flash. The display in display zone 4 must fluctuate within the following control range: Alternator warning lamp OFF: ●...
  • Page 108 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Activating diesel particulate filter warning lamp -K231- – Press button. → The diesel particulate filter warning lamp -K231- is activated. ● The warning lamp must flash. Warning lamp does not flash: –...

  • Page 109: Measured Value Blocks, Engine Codes Cjda, Cjdd

    ◆ Ensure that there is sufficient clearance to all moving or hot components. To prevent injuries to persons and/or destruction of the injection and glow plug system, the following must be noted: 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 110: Reading Measured Value Block

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Always switch off the ignition before connecting or discon- necting injection and glow plug system wiring or tester ca- bles. ◆ If the engine is to be turned at starter speed without starting, e.g.

  • Page 111: Evaluating Measured Value Blocks At Idling Speed

    ⇒  P age 105 5.3.1 Display group 1 - Injected quantity Test prerequisites ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ● Intake air temperature < 40°C. 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 112: Display Group 2 - Idling Speed

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone Engine speed 760...940 rpm ⇒  P age 96 Average injection quantity 3.0...9.0 mg/stroke Pressure in high-pressure fuel system 170.0...350.0 bar (actual) Coolant temperature...

  • Page 113: Display Group 3 - Exhaust Gas Recirculation

    Start of main injection activation -5...5°CrS Duration of main injection activation 350...700 ms Pressure in high-pressure fuel system 170...350 bar (actual) Evaluation: display group 4, display zone 2 - start of main injection activation: 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 114: Display Group 7 - Temperatures

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display shows Possible cause of fault Fault remedy Above specification – Run engine at increased speed to ◆ Engine too cold warm up, and repeat test 5.3.5 Display group 7 - Temperatures Test prerequisites ●...

  • Page 115: Display Group 11 - Charge Pressure Control

    The values displayed at “idling speed” are not relevant. 5.3.8 Display group 12 - Status Test prerequisites ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ● Intake air temperature < 40°C. 5 Measured value blocks, engine codes CJDA, CJDD...
  • Page 116 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone ⇒  P age 100 Glow plug system status 1111 1111 Glow period (in seconds) xx,x s Voltage supply from automatic glow peri- Approx.

  • Page 117: Display Group 13 - Smooth Running Control 1

    5.3.10 Display group 20 - Fuel rail values 3 Test prerequisites ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ● Intake air temperature < 40°C. 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 118: Display Group 30 - Pedal Encoder

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone Engine speed 760...940 rpm Pressure in high-pressure fuel system 170...350 bar (specified) ⇒  P age 102 Pressure in high-pressure fuel system 170...350 bar (actual) ⇒ ...

  • Page 119: Display Group 34 - Charge Pressure Positioner

    ● Engine warm, coolant temperature not below 80°C. ● Intake air temperature < 40°C. Display Operating mode or component Specification Evaluation zone Engine speed 760...940 rpm ⇒  P age 104 Exhaust gas temperature ahead of turbo- 80...300 °C charger 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 120: Display Group 100 - Diesel Particulate Filter, Exhaust Gas Temperature Sender, Pressure Differential Sender

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone Exhaust gas temperature ahead of diesel 80...200 °C particulate filter Evaluation: display group 99, display zone 2 - exhaust gas temperature Display shows Possible cause of fault...

  • Page 121: Display Group 106 - Diesel Particulate Filter, Regeneration 6

    Fault remedy Higher than specifi- – Renew diesel particulate filter ◆ Soot level too high cation ⇒  P age 427 Evaluation: display group 108, display zone 2 - diesel par- ticulate filter, regeneration 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 122: Evaluating Measured Value Blocks At Full Load

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display shows Possible cause of fault Fault remedy Higher than specifi- – Renew diesel particulate filter ◆ Calculated soot level too high cation ⇒  P age 427 Evaluation: display group 108, display zone 3 - diesel par- ticulate filter, regeneration Display shows...

  • Page 123: Display Group 3 - Exhaust Gas Recirculation

    ● Engine warm, coolant temperature not below 80°C ● Engine speed 2800…3200 rpm ● Engine at full load Display Operating mode or component Specification Evaluation zone Engine speed 2800...3200 rpm Intaken air mass (specified): 450...950 mg/stroke 5 Measured value blocks, engine codes CJDA, CJDD...

  • Page 124: Display Group 8 - Torque Limit 1

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone ⇒  P age 97 Intaken air mass (actual): Approx. intaken air mass (specified) Duty cycle of exhaust gas recirculation 80...100 % valve Evaluation: display group 3, display zone 3 - intaken air...

  • Page 125: Display Group 11 - Charge Pressure Control

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 5.4.5 Display group 11 - Charge pressure control Note ◆ To perform the test increase engine speed from 1500 rpm to full throttle at full load. Note conditions for measurements at ⇒ ...

  • Page 126: Safety Precautions

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ At idling speed ⇒  “ Evaluating measured value blocks at idling speed” on page 111, ◆ At full load ⇒  “ Evaluating measured value blocks at full load (engine code CPYA)”...
  • Page 127 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 are applicable for an engine temperature of at least 80°C ⇒ display group 1, display zone 4. Test procedure – Start engine and run at idling speed. –...
  • Page 128 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ 34 - Charge pressure positioner ⇒  P age 119, ◆ 99 - Exhaust gas temperature sender ⇒  P age 121, ◆ 100 - Diesel particulate filter, exhaust gas temperature, dif- ⇒ ...
  • Page 129 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone Engine speed 880...1090 rpm ⇒  P age 113 Accelerator position 0.0 % ◆ If accelerator position sender -G79- is installed Accelerator pedal switch positions Coolant temperature...

  • Page 130: Display Group 245

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.3.4 Display group 4 - Activation of injectors -N30...N33- Test prerequisites ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ●...
  • Page 131 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Details of temperature specifications are not possible. When the engine is cold the fuel, intake air and coolant temperatures must equate approximately to ambient temperature. If one of the temperature readings is noticeably different, test the relevant sender. Evaluation: Display group 7, display zone 1 - fuel tempera- ture Display shows...
  • Page 132 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.3.8 Display group 11 - Charge pressure control Test prerequisites ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ● Intake air temperature < 40°C. Display Operating mode or component Specification...
  • Page 133 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Significance if display = 1 Dis- Glow plug system status play show 1011 Post-heating 0000 1111 Intermediate heating 0000 0011 Standby-heating 0000 1011 Waiting for post-heating 0001 1111 Waiting for intermediate heating...
  • Page 134 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ The injection system provides idling speed smooth running control. There may be differences in performance between the individual cylinders (component tolerances, jet flow rate, compressions, etc.) which are recognised and compensated for by selective injection quantities.

  • Page 135: Display Group

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display shows Possible cause of fault Fault remedy ⇒  P age 391 Deviation from – -N276- Check. ◆ Fuel pressure regulating valve -N276- specification defective 6.3.12 Display group 30 - Pedal encoder Test prerequisites ●...

  • Page 136: Display Group 250

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone Engine speed 880...1090 rpm Charge pressure positioner (specified) 90...101 % ⇒  P age 120 Charge pressure positioner (actual) 90...101 % ⇒ ...
  • Page 137 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.3.17 Display group 85 Display Operating mode or component Value range Evaluation zone 0...2550 m 0...255 0..255 Engine start counter 0 - ? 6.3.18 Display group 97 Display Operating mode or component Value range...

  • Page 138: Display Group 254

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ● Intake air temperature < 40°C. Display Operating mode or component Specification Evaluation zone...
  • Page 139 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.3.22 Display group 108 - diesel particulate filter, regeneration 8 Test prerequisites ● Secure vehicle/machine ● Engine running at idling speed. ● Engine warm, coolant temperature not below 80°C. ●...
  • Page 140 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.3.23 Display group 245 Display Operating mode or component Value range Evaluation zone Thermal management timer since last 00000000 .. 11111111 successful regeneration and ash deposit mass adaptation, high byte (only CPYA and CPYB) Thermal management timer since last...

  • Page 141: Evaluating Measured Value Blocks At Full Load (Engine Code Cpya)

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.3.26 Display group 250 Display Operating mode or component Value range Evaluation zone Working speed control switch, specified 0 .. 5865 rpm engine speed Specified engine speed via buttons 0 ..

  • Page 142: Display Group 1 - Injected Quantity

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age Read measured value block 110. Note Due to the various use cases of industrial engines, check whether the engine attains full load under the respective operat- ing conditions before performing measurements at full load.

  • Page 143: Display Group 3 - Exhaust Gas Recirculation

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display shows Possible cause of fault Fault remedy – Check fuel supply system ◆ Shortage of fuel ⇒  P age 298, removing and installing ◆ Air in fuel system parts of fuel supply system ⇒ ...

  • Page 144: Display Group 8 - Torque Limit 1

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display shows Possible cause of fault Fault remedy Below specification – Check exhaust gas recirculation sys- ◆ Excessive exhaust gas recirculation ⇒  P age 436 –...

  • Page 145: Evaluating Measured Value Blocks At Full Load (Engine Code Cpyb)

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone ⇒  P age 129 Charge pressure (actual) 1600...1900 mbar Duty cycle of charge pressure control sol- 35...70 % enoid valve Evaluation: display group 11, display zone 3 - charge pres- sure (actual)

  • Page 146: Display Group 1 - Injected Quantity

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 6.5.2 Display group 1 - Injected quantity Note ◆ To perform the test increase engine speed from 1500 rpm to full throttle at full load. Note conditions for measurements at ⇒ ...

  • Page 147: Display Group 8 - Torque Limit

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● Engine warm, coolant temperature not below 80°C ● Engine speed 2200…2450 rpm ● Engine at full load Display Operating mode or component Specification Evaluation zone Engine speed 2200...2450 rpm...

  • Page 148: Display Group 11 - Charge Pressure Control

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Display Operating mode or component Specification Evaluation zone Engine speed 2200...2450 rpm Desired torque xxx Nm Torque limit xxx Nm Smoke limiting xxx Nm 6.5.5 Display group 11 - Charge pressure control Note ◆...

  • Page 149: Removing And Installing Engine

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 10 - Removing and installing engine Removing and installing engine WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! Special tools and workshop equipment...

  • Page 150: Notes On Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Spring-type clip pliers -VAS 5024- ◆ Engine and gearbox support -VAS 6095- ◆ Workshop hoist -VAS 6100- or work- shop hoist -V.A.G 1202 A- ◆...
  • Page 151 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 the various use cases it is not possible to specify a common procedure. Procedure WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions: ◆...

  • Page 152: Securing Engine To Assembly Stand

    Procedure Note The clutch and related components are not always in the scope of supply from Volkswagen. Adhere to the manufacturing speci- fications when performing any maintenance and repair work. – Check whether dowel sleeves for centring engine/gearbox have been fitted in cylinder block, insert if necessary.

  • Page 153: Specified Torques

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Align assembly mountings stress-free by rocking. ⇒  P age – Replenish coolant 284. – Then, read event memory of engine control unit, and clear ⇒ ...

  • Page 154: Crankshaft Group

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 13 - Crankshaft group Dismantling and assembling en- gine WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions:...
  • Page 155 Removing and installing bracket for ancillary units 144. ⇒  P age Assembly overview - toothed belt drive 146. Assembly overview - crankcase, engine codes CJDA, CJDD ⇒  P age 156. Assembly overview - crankcase, engine codes CPYA, CPYB, ⇒  P age CPYC, CPYD, CPYE 157.

  • Page 156: Assembly Overview - Poly V-Belt Drive, With Air Conditioner Compressor

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - poly V-belt drive, with air conditioner compressor 1 - Belt pulley and vibra- tion damper q Can only be instal- led in one position, holes are offset.

  • Page 157: Assembly Overview - Poly V-Belt Drive, Without Air Conditioner Compressor

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - poly V-belt drive, without air conditioner compres- 1 - Vibration damper q Installation position: hole in vibration damper must align over protrusion on crankshaft pulley. 2 - 23 Nm 3 - Alternator 4 - Ancillary bracket...
  • Page 158 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Swing tensioning element in -direction of arrow- to remove tension from poly V-belt. – Align holes -arrows-, and lock tensioning element in position using locking pin -T10060 A-. –...

  • Page 159: Poly V-Belt: Check Condition

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Procedure Note The poly V-belt repair kit with tools contains tool -T10367- and illustrated instructions. – Cut through the poly V-belt. – Proceed as described in illustrated instructions. After completing repairs always: –...

  • Page 160: Removing And Installing Ancillary Bracket

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew securing bolt -2- and remove poly V-belt tensioner -1-. Installing Install in reverse order. In the process, note the following: ◆ Renew bolt for tensioning element ◆...
  • Page 161 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew nut -1-, and remove retainer for connector of Hall sender —G40– -2-. Continuation for all engine codes – Unscrew bolts -6…1- and remove ancillaries bracket. Installing Install in reverse order.

  • Page 162: Assembly Overview - Toothed Belt Drive, Engine Codes Cjda, Cjdd, Without Crankshaft Seal

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Install alternator. Assembly overview - toothed belt drive, engine codes CJDA, CJDD, without crankshaft seal 1 - Toothed belt q Mark direction of ro- tation before remov- ing.
  • Page 163 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 15 - 10 Nm q Renew 16 - Idler pulley 17 - 50 Nm + turn (90°) further q Renew 18 - Hub q Use counterhold tool -T10051- to loosen and tighten. q To remove, use puller -T40064-. ⇒ ...

  • Page 164: Removing And Installing Engine Bracket

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing and installing engine bracket Removing – Attach lifting tackle -3033- as shown, and take up weight of engine using workshop hoist -V.A.G 1202 A- or workshop hoist -VAS 6100-.

  • Page 165: Assembly Overview - Toothed Belt Drive, Engine Codes Cpya, Cpyb, Cpyc, Cpye, With Crankshaft Seal

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - toothed belt drive, engine codes CPYA, CPYB, CPYC, CPYE, with crankshaft seal 1 - Toothed belt q Mark direction of ro- tation before remov- ing.

  • Page 166: Removing And Installing Toothed Belt Guard With Inspection Cover For Checking Tension Of Toothed Belt

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age 380 q Removing and installing 20 - 95 Nm 21 - Toothed belt pulley for fuel system high-pressure pump 22 - 23 Nm q Renew 23 - Coolant pump ⇒  P age 287 q Removing and installing 24 - 15 Nm 25 - Toothed belt guard upper part...

  • Page 167: Performing Visual Check Of Toothed Belt Tension

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew bolts -1- on upper part of toothed belt guard (qty. 2) as well as bolts -2- on lower part of toothed belt guard (qty. 4), and remove both parts of toothed belt guard.

  • Page 168: Assessing Wear On Tensioning Roller And Belt Pulleys

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Start the cold engine, and run it at idling speed. Note After the visual check has been completed, make sure to turn the inspection cover towards right until the triangle marks are properly aligned.

  • Page 169: Assessing Wear

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – If wear of high-pressure pump pulley -1- exceeds 0.50 mm, renew all toothed belt pulleys and rollers. The diameter of a new high-pressure pump pulley is 65.15 mm (+0.1 mm). –...
  • Page 170 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – If the toothed belt wear exceeds of the measuring field, the appropriate time for renewing the toothed belt must be specified for each individual scenario. The indicator should not be too close to the centre of the measuring field.

  • Page 171: Removing And Installing Crankshaft Protective Cover

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.15 Removing and installing crankshaft protective cover Removing – Loosen bolts -1- on vibration damper -2-, and remove vibra- tion damper. – Loosen bolts -3- on lower part of toothed belt guard -4-, and remove lower part of toothed belt guard.

  • Page 172: Assembly Overview - Crankcase, Engine Codes Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.16 Assembly overview - crankcase, engine codes CJDA, CJDD 1 - Cylinder block q Removing and in- stalling sealing flange and flywheel ⇒  P age 158. q Removing and in- stalling crankshaft ⇒ ...

  • Page 173: Assembly Overview - Crankcase, Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 14 - Poly V-belt tensioner, if fitted q Swing to slacken poly V-belt 15 - Sump q Clean sealing surface before fitting. q Install with silicone sealant D176404 A2 ⇒ ...

  • Page 174: Removing And Installing Sealing Flange And Flywheel

    Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 175: Assembly Overview - Sealing Flange, Belt Pulley End

    ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims. 2 Removing and installing sealing flange and flywheel...
  • Page 176 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - 180 Nm + turn (135°) further q Renew q Use counterhold -3415- to loosen and tighten. q Do not additionally oil or grease thread and shoulder. q Turning further can be done in several stages.

  • Page 177: Renewing Crankshaft Oil Seal - Pulley End

    Renewing crankshaft oil seal - pulley Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 178: Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Oil seal extractor -3203- ◆ Counterhold -3415- ◆ Assembly tool -T10053- ◆ Torque wrench (5…50 Nm) -V.A.G 1331- ◆...

  • Page 179: Installing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Using great pressure, screw oil seal extractor as far as pos- sible into oil seal. – Loosen knurled screw and turn inner part against crankshaft until oil seal is pulled out.

  • Page 180: Removing And Installing Crankshaft Sealing Flange, Pulley End

    ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims. Repair Group 13 - Crankshaft group...

  • Page 181: Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Counterhold -3415- ◆ Assembly tool -T10053- ◆ Torque wrench (5…50 Nm) -V.A.G 1331- ◆ Torque wrench (40… 200 Nm) -V.A.G 1332- Not illustrated: ◆...

  • Page 182: Installing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove crankshaft pulley. To do this, lock toothed belt pul- ley using counterhold -3415-. ⇒  P age – Drain engine oil 245. Note Observe environmental regulations for disposal. ⇒ ...

  • Page 183: Assembly Overview - Sealing Flanges And Flywheel

    ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims. 2 Removing and installing sealing flange and flywheel...
  • Page 184 Must seat on dowel sleeves. q Do not damage or bend when assembling. q The intermediate plate is not always in the scope of supply from Volkswagen. Adhere to the manufac- turing specifications when performing any maintenance and repair work.

  • Page 185: Renewing Crankshaft Sealing Flange - Flywheel End

    ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims. 2 Removing and installing sealing flange and flywheel...
  • Page 186 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Assembly tool -T10134- ◆ Torque wrench -V.A.G 1331- ◆ Tool insert 24 mm -V.A.G 1332/11- Not illustrated ◆ Vernier gauge ◆...

  • Page 187: Pressing Out Sealing Flange With Sender Wheel

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 E - Checking installation position of sender wheel on crankshaft ⇒  P age 176. ⇒  P age F - Re-pressing sender wheel 177. 2.5.1 Pressing out sealing flange with sender wheel Note For the sake of clarity, the work is performed with the engine re-...

  • Page 188: Pressing In Sealing Flange With Sender Wheel

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.2 Pressing in sealing flange with sender wheel Note ◆ The sealing flange with a PTFE seal is equipped with a seal- ing lip support ring. This support ring serves as a fitting sleeve and must not be removed prior to installation.
  • Page 189 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Clamp assembly device -T10134- in a vice on clamping sur- face -A- of threaded spindle. – Press assembly housing -C- downwards so that it lies on hexagon nut -B- -arrow-.

  • Page 190: B - Installing Assembly Tool -T10134- With Sealing Flange To Crankshaft Flange

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Upper edge of sender wheel and front edge of sealing flange must align -arrows-. – Place sealing flange with front side on assembly tool -T10134- so that locating pin -A- can be inserted in sender wheel hole -A-.

  • Page 191: C - Bolting Assembly Tool -T10134- To Crankshaft Flange

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Secure assembly tool -T10134- to crankshaft flange using hexagon socket head bolts -A-. Note Screw hexagon socket head bolts -A- into crankshaft flange (approx. 5 full turns). –...

  • Page 192: D - Pressing Sender Wheel Onto Crankshaft Flange Using Assembly Tool -T10134

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.6 D - Pressing sender wheel onto crankshaft flange using assembly tool -T10134- – Tighten hexagon nut of assembly tool -T10134- to 35 Nm us- ing torque wrench -V.A.G 1331- and tool insert, 24 mm -V.A.G 1332/11-.

  • Page 193: F - Re-Pressing Sender Wheel

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Install engine speed sender -G28- -arrow-, and tighten se- curing bolt to 5 Nm. ⇒  P age – Install sump 244. – Install intermediate plate. –...

  • Page 194: Removing And Installing Engine Speed Sender -G28

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing and installing engine speed sender -G28- WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! Special tools and workshop equipment required ◆...

  • Page 195: Removing And Installing Crankshaft

    Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 196: Assembly Overview - Crankshaft

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - crankshaft 1 - Bearing shells 1, 2, 4 and 5 q For bearing cap without oil groove. q For cylinder block with oil groove. q Do not interchange used bearing shells (mark).

  • Page 197: Pulling Needle Bearing, If Fitted, Out Of And Driving Into Crankshaft

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Honing dimen- Crankshaft Conrod sion main journal diam- journal diameter eter Basic dimension 54.00 -0.022 50.90 -0.022 -0.042 -0.042 Pulling needle bearing, if fitted, out of and driving into crankshaft Note The needle bearing in the crankshaft is not installed on all en-...

  • Page 198: Driving In

    Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 199: Assembly Overview - Pistons And Conrods

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age Bearing shells - installation position 186. ⇒  P age Checking piston projection at TDC 187. ⇒  P age 188 Piston and cylinder dimensions Assembly overview - pistons and conrods 1 - Piston rings q Offset gaps by 120°.
  • Page 200 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 q Insert bearing shells centrally. q Make sure it is firmly seated q Axial clearance, wear limit: 0.37 mm q Check radial clearance with Plastigage; wear limit: 0.08 mm. Do not rotate crankshaft when checking radial clearance.

  • Page 201: Separating New Conrods

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking ring-to-groove clearance Special tools and workshop equipment required ◆ Feeler gauges Test procedure – Clean ring groove before checking. Piston ring Clearance Wear limit 1st compression ring 0.06…0.09 0.25...

  • Page 202: Bearing Shells - Installation Position

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Mark cylinder allocation of conrod. – Lightly clamp the conrod in a vice using aluminium vice clamps, as shown in the illustration. Note ◆ To prevent damage to the conrod, only clamp conrod in light- ◆...

  • Page 203: Checking Piston Projection At Tdc

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking piston projection at TDC Special tools and workshop equipment required ◆ Measuring bridge -VW 382/7- ◆ End dimension plate -VW 385/17- Not illustrated: ◆ Dial gauge Test procedure Piston projection at TDC must be measured when installing new pistons or a short engine.

  • Page 204: Piston And Cylinder Dimensions

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Cylinder head gasket identification ◆ Part number = arrow 1 ◆ Holes = arrow 2 ◆ Production control code = arrow 3 (can be disregarded) Note ◆...

  • Page 205: Cylinder Head, Valve Gear

    Cylinder head Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 206: Assembly Overview - Cylinder Head

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ The plastic protectors fitted to protect the open valves must be removed only immediately before the cylinder head is fit- ted. ◆ If the cylinder head is replaced, all the coolant in the system must also be renewed.

  • Page 207: Removing And Installing Hall Sender -G40

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 11 - Gasket q Renew 12 - 25 Nm 13 - Lifting eye 14 - Cylinder head gasket q Renew ⇒  F ig. on page q Note marking 191. q After renewing, renew entire coolant. 15 - Hall sender -G40- q For camshaft position.
  • Page 208 – Remove toothed belt from idler pulley high-pressure pump ⇒  P age pulley. To do this, remove toothed belt 212. Engine codes CJDA, CJDD – Disconnect connector for Hall sender -G40- in -centre-. – Detach plug from its retainer. Engine codes CPYA, CPYB, CPYC, CPYD, CPYE...
  • Page 209 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Disconnect connector for Hall sender -G40- -5-. Continuation for all engine codes – Detach plug from its retainer. – Unscrew Hall sender -G40- -arrow-. –...

  • Page 210: Assembly Overview - Cylinder Head Cover, Engine Codes Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - cylinder head cover, engine codes CJDA, CJDD 1 - 5 Nm 2 - Fuel rail q With injection pipes. q Do not attempt to bend injector pipes to a different shape.
  • Page 211 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Disconnecting fuel return lines – With engine switched off, carefully pull return line connec- tions off injectors. To do this, press both clips downwards -arrow A- and simultaneously pull release pin upwards -arrow B-.

  • Page 212: Removing And Installing Cylinder Head Cover

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Lock fuel return line – After fuel return line has been pushed on completely, press locking pin downwards -arrow-. Tightening sequence – Screw on cylinder head cover hand-tight in the sequence -1 to 7.- –...
  • Page 213 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Socket -T40055- ◆ Pliers -3314- Removing – Remove noise insulation from injectors. – Pull connectors off injectors -A-, exhaust gas pressure sen- sor 1 -G450- -B- and fuel rail pressure sensor -C-. Caution Make sure that no wiring connections are damaged when disconnecting the connectors.
  • Page 214 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Carefully pull connector in direction of -arrow- off glow plug. – Open clamp -arrow- and pull line off fuel rail. Disconnecting fuel return lines Caution ●...
  • Page 215 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – With engine switched off, carefully pull return line connec- tions off injectors. To do this, press both clips downwards -arrow A- and simultaneously pull release pin upwards -arrow B-.
  • Page 216 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew bolts -arrows- and remove fuel rail. – Remove injectors. – Remove securing bolts for cylinder head cover and take off cylinder head cover. Installing Install in reverse order.
  • Page 217 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Attach fuel return line and press the two clips downwards as far as they will go -arrows-. – After fuel return line has been pushed on completely, press locking pin downwards -arrow-.

  • Page 218: Assembly Overview - Cylinder Head Cover, Engine Codes Cpya, Cpyb, Cpyc, Cpyd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - cylinder head cover, engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - High-pressure accu- mulator (fuel rail) q Do not attempt to reshape high-pres- sure lines.
  • Page 219 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 9 - Clamping plate 10 - Noise insulation ⇒  I tem 3 q Route fuel return lines in noise insulation guides. 11 - Injector seal q Renew if damaged or leaking 12 - Cap 13 - Gasket 14 - Grommet...
  • Page 220 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Check catches Caution ● Carefully pull fuel return lines upwards vertically when disconnecting, as the 4 catches -arrow- can fracture. ● After disconnecting, check the 4 catches -arrow- to see whether they are fractured or have broken off.

  • Page 221: Removing And Installing Cylinder Head Cover

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Tightening sequence – Bolt on cylinder head cover hand-tight in the sequence -1...6-. – Tighten bolts to 10 Nm in the sequence -1...6-. 1.4.1 Removing and installing cylinder head cov- Special tools and workshop equipment required ◆...
  • Page 222 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Open clips -1- and remove toothed belt guard -3-. – Remove pipe from cylinder head cover -arrow-. – Unscrew bolts -3-. – Unscrew union nuts -1- using socket -T40055-, and remove fuel line -2-.
  • Page 223 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Release connector -1- and pull off from fuel pressure sender -G247- -2-. – Pull cable guide -3- off fuel rail. – Release all connectors -1- and pull off from injectors (piezo injectors).
  • Page 224 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – With engine switched off, carefully pull return line connec- tions off injectors. To do this, press both clips downwards -arrow A- and simultaneously pull release pin upwards -arrow B-.
  • Page 225 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Hand-tighten cylinder head cover in the sequence -1 … 6-. – Tighten bolts in the sequence -1 … 6- to 10 Nm. – Apply a thin coat of diesel fuel to new O-rings on return-line connections.

  • Page 226: Renewing Toothed Belt And Toothed Belt Tensioning Roller For Camshaft Drive, Engine Co- Des Cjda, Cjdd, Cpya, Cpyb, Cpyc, Cpyd, Cpye

    – Then, fit toothed belt guard to middle -2- and -3- of toothed belt guard at the top. Renewing toothed belt and toothed belt tensioning roller for camshaft drive, en- gine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE WARNING Adhere to the general safety regulations and the notes on ⇒ ...
  • Page 227 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Locking pin -3359- ◆ Crankshaft stop -T10050- ◆ Counterhold -T10172- ◆ Counterhold tool adapt- er -T10172/4- ◆ Counterhold tool adapt- er -T10172/8- ◆...

  • Page 228: Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Spring-type clip pliers -VAS 5024- 1.5.1 Removing Note The toothed belt may only be adjusted on cold engines, as the indicator position on the tensioning element varies depending on the engine temperature.
  • Page 229 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove lower toothed belt guard. To do this, unscrew bolts -arrows-. – Turn engine to TDC position, and pin crankshaft pulley using crankshaft stop -T10050-. To do this, push crankshaft stop into toothed belt pulley splines from face end.

  • Page 230: Installing, Tensioning

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Loosen tensioning roller securing nut -1-. – Using socket -T10264-, turn eccentric of tensioning roller an- ti-clockwise -arrow- until the tensioning roller can be locked with locking pin -T10265-.
  • Page 231 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Lock camshaft hub with locking pin -3359-. To do this, slide locking pin through outer free elongated hole into hole in cyl- inder head. –...
  • Page 232 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Ensure that tensioning roller seats correctly in rear toothed belt guard -arrow-. – Screw eccentric of tensioning roller clockwise carefully using angled screwdriver -T10264-. Indicator -2- must be roughly past the centre of the gap in the base plate (rectifies itself during pretensioning).
  • Page 233 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ During the following checking procedure, only the camshaft and crankshaft must be secured in position. It is very difficult to find the securing position of the high-pressure pump hub again.

  • Page 234: Checking Compression

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Camshaft sprocket: 45° further. Counterhold with counter- hold tool -T10172- and adapters -T10172/4-. ◆ High pressure pump sprocket: 90° further. Counterhold with counterhold tool -T10172- and adapters -T10172/8-. –...
  • Page 235 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Check compression using compression tester -V.A.G 1763-. Note ⇒ Operating manual. Using the compression tester – Turn over engine until tester shows no further pressure in- crease.

  • Page 236: Removing And Installing Cylinder Head

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing and installing cylinder head Special tools and workshop equipment required ◆ Guide pins -3070- ◆ Diesel injection pump locking pin -3359- ◆ Crankshaft stop -T10050- ◆...

  • Page 237: Notes On Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Torque wrench -V.A.G 1331- ◆ Torque wrench -V.A.G 1332- ◆ Drip tray for workshop hoist -VAS 6208- Not illustrated: ◆ Container for removed parts -V.A.G 1698- ◆...
  • Page 238 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions: ◆ Route all the various lines (e.g. for fuel, hydraulics, activated charcoal filter system, coolant, refrigerant, brake fluid and vacuum) and electrical wiring in their original positions.
  • Page 239 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Engine codes CJDA, CJDD Caution The exhaust gas temperature sender 1 -G235- covers the upper threaded connection of the turbocharger support and must not be bent. It must therefore be removed.
  • Page 240 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew securing bolt -arrow- for toothed belt guard. – Unscrew securing nut of toothed belt tensioning roller. – Disconnect connector for Hall sender -G40- -centre-. –...

  • Page 241: Notes On Installing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.7.2 Notes on installing Note ◆ Always renew cylinder head bolts. ◆ In case of repair, carefully remove gasket remains from cyl- inder head and cylinder block. Ensure that no long scores or scratches are made on the surfaces.

  • Page 242: Removing And Installing Vacuum Pump

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Stage IV = 90° Note After repair work it is not necessary to retighten the cylinder head bolts. – Secure toothed belt rear guard to cylinder head. –...

  • Page 243: Repairing Valve Gear

    Repairing valve gear Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 244: Assembly Overview - Valve Gear

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - valve gear 1 - Seal q Do not additionally oil or grease the oil seal sealing lip. q Before installing, re- move residual oil from camshaft jour- nal using a clean cloth.

  • Page 245: Valves

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 13 - Valve spring plate 14 - Valve cotter 15 - Cap q Renew Valves 2.2.1 Valve dimensions Note ◆ Valves must not be reworked. Only lapping-in is permitted. Dimension Inlet valve Exhaust valve Diameter a 26.60...

  • Page 246: Renewing Valve Stem Seals

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Renewing valve stem seals Special tools and workshop equipment required ◆ 10 mm jointed spanner -3220- ◆ Valve stem seal puller -3364- ◆ Valve stem seal fitting tool -3365- ◆...
  • Page 247 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Screw adapter -VAS 5161/11- hand-tight into glow plug hole of relevant cylinder. – Insert drift -VAS 5161/3- into guide plate and knock valve cotters loose using a plastic hammer. –...
  • Page 248 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove valve stem oil seals using valve stem seal puller -3364-. Note ◆ A plastic sleeve -A- is included with the new valve stem oil seals.

  • Page 249: Removing And Installing Camshaft

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Engine is not to be rotated for approx. 30 minutes after in- stalling camshafts. The hydraulic compensation elements must settle (otherwise valves will strike pistons). ◆...

  • Page 250: Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Torque wrench -V.A.G 1331/- ◆ Torque wrench -V.A.G 1332/- ◆ Silicone adhesive sealant D 176501 A1 ⇒  P age Removing 234. ⇒  P age Installing 235.

  • Page 251: Installing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Fit puller -T10052- and align it with holes in hub. – Tighten securing bolts -1-. – Apply tension to hub by evenly tightening puller -2- until hub separates from taper of camshaft.
  • Page 252 -T40094/8- into groove on inlet camshaft. – Now set exhaust camshaft in place and lock by inserting -cover T40094/11- into groove -arrow-. Engine codes CJDA, up to 02.10 – If necessary, fit clamping tool -T40096/1- onto exhaust cam- shaft gears.
  • Page 253 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Tighten clamping tool -T40096/1- using knurled thumb wheel so that faces of gear teeth are in alignment. If necessary, use 13 mm open-end spanner. –...
  • Page 254 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ The sealant beads must not be thicker than specified, other- wise excess sealant could enter the camshaft bearings. – Take camshafts out of camshaft fitting tool -T40095- together with retaining frame and clamping tool -T40094-.

  • Page 255: Removing And Installing Camshaft Oil Seal

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Tighten hub securing bolt -1- to 100 Nm. Use counterhold tool -T10051- for this. – – Push camshaft toothed belt pulley onto hub. Note The toothed segment -arrow- of the camshaft belt pulley must be on top.

  • Page 256: Engines Up To

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.1 Engines up to 08.09 Special tools and workshop equipment required ◆ Fitting tool -10-203- ◆ Oil seal extractor -3240- ◆ Torque wrench (5…50 Nm) -V.A.G 1331- ◆...
  • Page 257 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Lubricate threaded head of oil seal extractor, place it in posi- tion and, exerting firm pressure, screw it into oil seal as far as possible. –...

  • Page 258: Engines As Of

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.2 Engines as of 09.09 Special tools and workshop equipment required ◆ Fitting tool -V.A.G 10-203- ◆ Oil seal extractor -T10443- ◆ Torque wrench -V.A.G 1331/- ◆...
  • Page 259 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ The clamps of the seal extractor contain grub screws. Only one of these grub screws -arrow- causes clamping; the oth- ers are permanently fixed. –...

  • Page 260: Lubrication

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 17 - Lubrication Engine oil WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! Note The oil level must not be above the max.

  • Page 261: Draining Or Extracting Engine Oil

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Renewing engine oil filter, engine codes CJDA, CJDD, CPYA, ⇒  P age CPYB, CPYC, CPYD, CPYE 246. ⇒  P age Fill engine oil 247. ● The engine oil must be changed regularly as per the specifi- cations in the service schedule.

  • Page 262: Cpye

    ◆ Torque specifications must not be exceeded. ◆ Excessive torque can cause leaks in the area of the oil drain plug or even damage. 1.2.2 Renewing engine oil filter, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE Removing Note ◆...

  • Page 263: Replenishing Engine Oil

    ◆ Therefore, also observe the specifications of the machine manufacturer. Engine codes With oil filter Engine oil specifi- change cations CJDA 4.3 l 507 00 CJDD 4.3 l 507 00 CPYA 4.3 l...
  • Page 264 ◆ Using only the engine oil approved by Volkswagen expressly for this engine, top up the oil in small gradual amounts. ◆ To avoid overfilling, wait after each pour to allow the engine oil to flow into the oil sump up to the marking on the engine oil dipstick.

  • Page 265: Parts Of Lubrication System

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 WARNING Engine oil can ignite if it comes in contact with hot en- gine components. This may cause fire, burns and other serious injuries. ◆ Always make sure that the cap of the engine filler opening is securely closed after refilling.

  • Page 266: Assembly Overview - Oil Pump, Sump

    Assembly overview - oil pump, sump Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 267: Engine Codes Cjda, Cjdd

    ⇒  P age Engine codes CJDA, CJDD 251. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 254. 2.1.1 Engine codes CJDA, CJDD Assembly overview - oil filter bracket and oil cooler 2 Parts of lubrication system...
  • Page 268 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - 15 Nm 2 - Sealing flange q With seal. q Must be positioned on dowel sleeves. q Removing and in- stalling. q Install with silicone sealant D 176 404 A2. q Do not additionally oil or grease the oil seal sealing lip.
  • Page 269 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 17 - Oil level and oil temperature sender -G266- q Black connector, 3-pin. ⇒  F ig. on page 253 q Removing and installing 18 - Seal q Renew 19 - Oil pump q With 12 bar pressure relief valve q Before installing, check that both dowel sleeves for centring oil pump on cylinder block are fitted.

  • Page 270: Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.1.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE – Assembly overview - oil filter bracket and oil cooler Repair Group 17 - Lubrication...
  • Page 271 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - 15 Nm 2 - Sealing flange q With seal. q Must sit on dowel sleeves q Removing and in- stalling. q Insert with silicone sealant D 176 404 A2. q Do not additionally oil or grease the oil seal sealing lip.
  • Page 272 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Check oil pump for free movement. ◆ It should be possible to turn toothed belt pulley easily with 1 finger. ◆ Renew if tight/sticking. 12 - Intake manifold q Clean strainer if soiled.

  • Page 273: Removing And Installing Sump

    Removing and installing sump Note ◆ The repair work described in this chapter must be carried out in a Volkswagen dealership only. Go to a Volkswagen deal- ership. ◆ If these instructions are not adhered to and damage results, Volkswagen is exempt from any liability and warranty claims.

  • Page 274: Removing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ 10 mm jointed spanner -VAS 3185- ◆ Allen key, long reach 5 mm -T10058- ◆ Torque wrench (5…50 Nm) -V.A.G 1331- ◆...

  • Page 275: Installing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Loosen sump with light blows of a rubber headed hammer if necessary. – Remove sealant residue from cylinder block with a flat scra- per. WARNING Wear eye protection.

  • Page 276: Oil Filter Bracket, Oil Cooler And Oil Pressure Switch

    ⇒  P age Observe rules for cleanliness 354. Oil filter bracket, oil cooler and oil pres- sure switch, engine codes CJDA, CJDD Assembly overview - oil filter bracket and oil cooler ⇒  P age 261. Repair Group 17 - Lubrication...

  • Page 277: Assembly Overview - Oil Filter Bracket And Oil Cooler

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing and installing oil filter bracket together with oil cooler ⇒  P age 262. ⇒  P age 264 Checking oil pressure and oil pressure switch -F1- Note Observe general notes on the lubrication system.

  • Page 278: Removing And Installing Oil Filter Bracket Together With Oil Cooler

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 q Fit into lugs on oil cooler. 12 - Oil cooler q Ensure clearance to adjacent components. q Checking oil cooler for leaks 13 - Seal q Renew 14 - Cap, 25 Nm q Loosen and tighten with socket AF 36 mm -T10125-.
  • Page 279 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove charge air pipe -1- and coolant hose -2-. – Remove securing bolts of dipstick guide tube. – Pull guide tube upwards out of crankcase and press it slight- ly aside.

  • Page 280: Checking Oil Pressure And Oil Pressure Switch -F1

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.3 Checking oil pressure and oil pressure switch -F1- Special tools and workshop equipment required ◆ Oil pressure tester -V.A.G 1342- ◆ Diode test lamp -V.A.G 1527 B- ◆...

  • Page 281: Oil Filter Bracket, Oil Cooler And Oil Pressure Switch, Engine Codes Cpya, Cpyb, Cpyc

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove oil pressure switch -F1- and screw into oil pressure tester. – Screw oil pressure tester into oil filter bracket in place of oil pressure switch.

  • Page 282: Assembly Overview - Oil Filter Bracket, Oil Cooler

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.1 Assembly overview - oil filter bracket, oil cooler Caution Seals 11 and 14 must not be lubricated with oil. The coolant seals would otherwise swell up. Repair Group 17 - Lubrication...
  • Page 283 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - O-ring q Renew 2 - Cap, 25 Nm 3 - O-ring q Renew 4 - O-ring q Renew 5 - Oil filter element q Observe change in- tervals. 6 - Guide tube q Renew O-ring. 7 - 10 Nm 8 - Spreader clip 9 - Oil cooler...

  • Page 284: Removing And Installing Oil Filter Bracket With Engine Oil Cooler

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.2 Removing and installing oil filter bracket with engine oil cooler Special tools and workshop equipment required ◆ Removal lever -80 - 200- ◆ Torque wrench -V.A.G 1410- ◆...
  • Page 285 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing – Remove oil filter element -3-. – Unbolt dipstick guide tube. – Drain coolant. – Push clip -3- off guide tube -1- for oil dipstick with removal lever -80 - 200-.

  • Page 286: Removing And Installing Oil Cooler

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove coolant hose -3-. To do this, release hose clip -2-. – Place used oil collection and extraction unit -V.A.G 1782- un- der engine. –...
  • Page 287 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Drip tray for workshop hoist -VAS 6208- ◆ Hose clip pliers -VAS 6362- Removing – Bring lock carrier into service position ⇒  G eneral body re- pairs;...
  • Page 288 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove bolts -arrows-. – Remove engine oil cooler from housing. Installing Install in reverse order. In the process, note the following: Note ◆ Renew gaskets, seals and O-rings. ◆...

  • Page 289: Removing And Installing Oil Pressure Switch -F1

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.4 Removing and installing oil pressure switch -F1- Special tools and workshop equipment required ◆ Torque wrench (5…50 Nm) -V.A.G 1331- Removing Note ◆ Oil pressure switch -F1- is installed on rear left of cylinder head.

  • Page 290: Checking Oil Pressure And Oil Pressure Switch -F1

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.5 Checking oil pressure and oil pressure switch -F1- Special tools and workshop equipment required ◆ Oil pressure tester -V.A.G 1342- ◆ Voltage tester -V.A.G 1527 B- ◆...
  • Page 291 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove oil pressure switch -F1- -2- and screw into oil pres- sure tester -V.A.G 1342-. – Screw tester into oil filter bracket in place of oil pressure switch.

  • Page 292: Cooling

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 19 - Cooling Removing and installing parts of cooling system WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow-...
  • Page 293 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Hoses are secured with spring-type clips. In case of repair, only use spring-type clips. ◆ Spring-type clip pliers -VAS 5024- are recommended for in- stallation of spring-type clips.

  • Page 294: Parts Of Cooling System, Engine Side, Engine Codes Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Parts of cooling system, engine side, engine codes CJDA, CJDD 1 - Gasket q Renew 2 - Connection q Coolant hose sche- matic diagram ⇒  P age 280. 3 - 9 Nm 4 - Retaining clip...

  • Page 295: Parts Of Cooling System, Engine Side, Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Parts of cooling system, engine side, engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - Gasket q Renew 2 - Connection q Coolant hose sche- matic diagram ⇒  P age 280.

  • Page 296: Coolant Hose Schematic Diagram

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Coolant hose schematic diagram 1 - Expansion tank 2 - Cylinder head/cylin- der block 3 - Exhaust gas recircu- lation valve 4 - Heat exchanger for heater, optional 5 - Connection q On cylinder head. 6 - Engine oil cooler 7 - Coolant return hose q To radiator...

  • Page 297: Checking Frost Protection, Replenishing Coolant Additive If Necessary

    1.4.1 Checking frost protection, replenishing coolant additive if necessary Note ◆ Replenish only new coolant according to the Volkswagen specification. ◆ The coolant level must be between the marks on the coolant expansion tank. Do not fill up over the top line of the marked area.

  • Page 298: Checking Coolant Level, Replenishing Coolant Additive If Necessary

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Refractometer -T10007 A- Note Read precise value for the following tests at bright/dark boun- dary. Using a pipette, place a drop of water on the glass to im- prove the readability of the bright/dark boundary.

  • Page 299: Mixture Ratio

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.4.3 Mixture ratio: Caution Only distilled water may be used for mixing. Tap or well wa- ter does not have the required quality to ensure the effec- tiveness of coolant.

  • Page 300: Draining And Filling Coolant

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Draining and filling coolant Special tools and workshop equipment required ◆ Refractometer -T10007- ◆ Adapter -V.A.G 1274/8- ◆ Drip tray -V.A.G 1306- or drip tray -VAS 6208- ◆...

  • Page 301: Filling

    The water used in the coolant mixture has a great influence on its effectiveness. Because the water quality differs from country to country and even region to region, Volkswagen has decided to define the quality of the water to be used in the coolant sys- tem.
  • Page 302 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Caution Only distilled water may be mixed with G12 plus-plus. The use of distilled water ensures optimum protection against corrosion. Note ◆ Use only coolant additive G 12 plus-plus in accordance with TL VW 774 G.

  • Page 303: Cpye

    Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE Renewing coolant pump, engine codes CPYA, CPYB, CPYC, ⇒  P age CPYD, CPYE, CJDA, CJDD 288.

  • Page 304: Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.6.1 Renewing coolant pump, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE Special tools and workshop equipment required ◆ Refractometer -T10007- ◆ Drip tray -V.A.G 1306- or drip tray -VAS 6208- ◆...
  • Page 305 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove securing bolts -1- for coolant pump -2- and carefully remove coolant pump. Installing Installation is carried out in the reverse order. When installing, note the following: –...

  • Page 306: Removing And Installing 4/2-Way Valve With Thermostat

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing and installing 4/2-way valve with thermostat Special tools and workshop equipment required ◆ 10 mm jointed spanner -3185- ◆ Refractometer -T10007- ◆ Allen key, long reach 5 mm -T10058- ◆...
  • Page 307 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Pull coolant hoses off connections -A, B and D-. – Pull coolant pipe out of connection -C-. – Remove securing bolts -3- for 4/2-way valve -2-. –...

  • Page 308: Checking Cooling System For Leaks

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking cooling system for leaks Special tools and workshop equipment required ◆ Cooling system tester -V.A.G 1274 B- ◆ Adapter for cooling system tester -V.A.G 1274/8- ◆...

  • Page 309: Checking Oil Cooler For Leaks

    The pressure relief valve must open. If the pressure relief valve does not open: – Renew cap. Checking oil cooler for leaks ⇒  P age Engine codes CJDA, CJDD 294. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 296.

  • Page 310: Engine Codes Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.9.1 Engine codes CJDA, CJDD Special tools and workshop equipment required ◆ Refractometer -T10007- ◆ Hose clips, up to 25 mm in diameter -3094- ◆ Cooling system tester -V.A.G 1274-...
  • Page 311 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Test procedure – Clamp off supply and return lines to oil cooler using hose clips, up to 25 mm -VAS 3094-. – Loosen hose clips -arrows- using spring-type clip pliers -VAS 5024-.

  • Page 312: Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.9.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE Special tools and workshop equipment required ◆ Refractometer -T10007- ◆ Hose clamps up to 25 mm -3094- ◆...
  • Page 313 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Collect escaping coolant with drip tray for workshop cranes -VAS 6208-. ◆ Collect leaking engine oil with an absorbent cleaning cloth, if necessary. Checking when removed –...

  • Page 314: Fuel Supply System

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 20 - Fuel supply system Removing and installing parts of fuel supply system WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow-...

  • Page 315: Safety Precautions When Working On Fuel Supply System

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Hose connections are secured with either spring-type or clamp-type clips. ◆ Always renew crimp-type clips with spring-type clips. ◆ Fuel hoses on engine must be secured with spring-type clips only.

  • Page 316: Rules For Cleanliness

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 WARNING Danger of burning from very hot fuel. ◆ In extreme cases, the fuel lines and the fuel can reach a temperature of 100 °C. Allow the fuel to cool down before disconnecting the lines - danger of scalding.

  • Page 317: Procedure When Filling With Incorrect Fuel

    – Empty fuel tank as far as possible via fuel filler neck using fuel extractor -VAS 5190-. Engine codes CJDA, CJDD Pull off fuel supply line to high-pressure pump ahead of strainer. Engine codes CPYA, CPYB, CPYC, CPYD, CPYE Pull fuel supply line from fuel pump -V393 (Inline EKP)- to fuel filter off fuel filter.

  • Page 318: Step 2 (Engine Was Not Started With Incorrect Fuel)

    – Empty fuel tank as far as possible via fuel filler neck using fuel extractor -VAS 5190-. Engine codes CJDA, CJDD Pull off fuel supply line to high-pressure pump ahead of strainer. Engine codes CPYA, CPYB, CPYC, CPYD, CPYE Pull fuel supply line from fuel pump -V393 (Inline EKP)- to fuel filter off fuel filter.

  • Page 319: Step 4 (There Are No Filings In Fuel Tank And Strainer)

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Fuel filter ⇒  P age 304. – Fill up machine. ⇒  P age – Bleeding fuel system 383. – Perform road test. 1.3.4 Step 4 (There are no filings in fuel tank and strainer) –...

  • Page 320: Step 6 (There Are No Filings In High-Pressure Pump)

    ⇒  P age Engine codes CJDA, CJDD 304. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 307. 1.4.1 Engine codes CJDA, CJDD ⇒  P age Versions of upper part of fuel filter 305. Repair Group 20 - Fuel supply system...

  • Page 321: Upper Part Of Fuel Filter

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - Fuel line q Make sure it is firm- ly seated q Connection over- ⇒  P age view 305. 2 - 5 Nm 3 - Washer 4 - Fuel line q Make sure it is firm- ly seated q Connection over- ⇒ ...
  • Page 322 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Fuel filter upper part, type A 1 - 8 Nm 2 - (Not necessarily installed) plug for water extraction (remove and extract about 100 cm of liquid using hand vacuum pump with accessories -V.A.G 1390- and water drainage container -V.A.G 1390/1-, renew seal).

  • Page 323: Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.4.3 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - Fuel filter bracket 2 - Fuel filter q The stamped ar- rows on the filter mark the fuel input and output.

  • Page 324: Renewing Fuel Filter

    There is too much water in the entire fuel system. Drain water from the entire fuel system. – Drain all components of fuel system which are not in the scope of supply from Volkswagen. ⇒ Refer to documenta- tion of respective manufacturer. ⇒  P age –...

  • Page 325: Renewing Fuel Filter Or Upper Part Of Fuel Filter Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.6.1 Renewing fuel filter or upper part of fuel fil- ter CJDA, CJDD Special tools and workshop equipment required ◆ Diesel extractor -VAS 5226- ◆ Angle driver -VAS 6543-...
  • Page 326 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Upper part of fuel filter can be raised at assembly groove -arrow A- using an angled screwdriver -VAS 6543-. ◆ The size of the assembly groove can vary depending on ver- sion of upper part.
  • Page 327 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Moisten new seal -1- with diesel and insert seal into upper part of fuel filter -arrows-. – Insert upper part of fuel filter with seal correctly onto lower part of fuel filter and press on evenly until the upper part of fuel filter seats completely.

  • Page 328: Renewing Fuel Filter, Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.6.2 Renewing fuel filter, engine codes CPYA, CPYB, CPYC, CPYD, CPYE Special tools and workshop equipment required ◆ Hose clip pliers -VAS 6340- Note ◆ Ensure that no diesel fuel comes into contact with the cool- ant hoses.

  • Page 329: Removing And Installing Supplementary Fuel Pump -V393- (Inline Electronic Fuel Pump)

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Push new fuel filter -2- into fuel filter bracket -1- until it en- gages. – Fit fuel lines -3- and -4-, and secure them with clamps. Bleeding fuel system Procedure: Note...

  • Page 330: Checking Components And Functions

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Disconnect connector from fuel temperature sender -G81- -arrow-, loosen clamp -1-, and pull fuel supply line off high- pressure pump. – Unscrew securing bolts of supplementary fuel pump -V393-. Installing Install in reverse order.
  • Page 331 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Connect vehicle diagnosis, testing and information system -VAS 5051/B- using diagnostic cable -VAS 5051B/1-. Test prerequisites ● Battery voltage at least 11.5 V ● Fuel filter OK. ●...

  • Page 332: Checking Accelerator Pedal Position Sender -G79-, If Fitted

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 If no fault is found: Renew fuel pump. Note Check fuel system for leaks. Checking accelerator pedal position sender -G79-, if fitted Special tools and workshop equipment required ◆...
  • Page 333 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● The accelerator position value must increase continuously. Specification at full throttle position: 100.0%. Display zone 3: ● The 5th digit from the left must change to 0. Display: xxxx0xxx –...
  • Page 334 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Renew accelerator position sender -G79-. – Then, read event memory of engine control unit, and clear ⇒  P age event memory if necessary 26, read event memory. If no wiring fault is detected and no voltage was present be- tween contacts 2 + 3 and 1 + 5: –...

  • Page 335: Turbocharging/Supercharging

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 21 - Turbocharging/supercharging Charge air system with turbo- charger WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions:...

  • Page 336: Safety Precautions When Working On Charge Air System With Turbocharger

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Safety precautions when working on charge air system with turbocharger WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions: ◆...

  • Page 337: Assembly Overview - Turbocharger With Attachments

    ◆ Renew self-locking nuts. ◆ Before installing the oil supply line, fill turbocharger with en- gine oil through connecting piece (engine codes CJDA, CJDD only). ◆ Before installing the turbocharger, fill the oil supply channel (smaller diameter) with a “splash” of engine oil “to prevent a dry start up”...

  • Page 338: Engine Codes Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.3.1 Engine codes CJDA, CJDD 1 - 10 Nm 2 - Oil supply line q Before installing oil supply line, ensure that it is not blocked. q Before installing, fill...
  • Page 339 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 13 - Retainer q For oil supply line. 14 - Heat shield 15 - Support q Between turbocharger and cylinder block. 16 - Seal q Renew 17 - Banjo bolt, 60 Nm q Renew 18 - Oil return pipe 19 - 15 Nm 20 - Pulsation damper 21 - 10 Nm...

  • Page 340: Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.3.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - Exhaust gas recircu- lation pipe q With flexible joint; do not bend flexible joint - danger of cracking.
  • Page 341 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 16 - Retainer q For electrical cables. 17 - Bolt q 15 Nm 18 - Heat shield 19 - Gasket q Renew 20 - Nut q Renew q 24 Nm 21 - Exhaust gas temperature sender 1 -G235- q Exhaust gas temperature sender ahead of turbocharger q 45 Nm q Lubricate thread of sender using high-temperature paste G 052 112 A3...

  • Page 342: Removing And Installing Turbocharger

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Installation position of O-ring and seals in pulsation damper 1 - Damper q With grooves. 2 - O-ring 3 - Seal q With spring. Installation position of exhaust gas temperature sender with angled cable guide Note When installing the exhaust gas temperature sender with an-...

  • Page 343: Removing

    – Disconnect connector for exhaust gas temperature sender 1 -G235- (exhaust gas temperature sender ahead of turbo- ⇒  P age charger) 321. Engine codes CJDA, CJDD ⇒  P age – Unscrew oil supply line on turbocharger 321. – Pull charge air pipe/connecting hose off turbocharger.
  • Page 344 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Remove exhaust gas temperature sender 1 -G235- -1- (ex- haust gas temperature sender ahead of turbocharger) ⇒  P age 432. ⇒  I tem 17 on –...

  • Page 345: Installing

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew bolts -arrows- and remove heat shield. – Remove nuts -arrows-. – Remove turbocharger together with exhaust manifold from cylinder head and turn so that the intake side is facing down- wards.

  • Page 346: Checking Charge Air System

    Note ◆ The components of the charge air system are not always in the scope of supply from Volkswagen. Adhere to the manu- facturing specifications when performing any maintenance and repair work. ◆ All hose connections are secured.

  • Page 347: Checking Charge Air System For Leaks

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking charge air system for leaks Special tools and workshop equipment required ◆ Charge air system tester -V.A.G 1687- ◆ Adapter -V.A.G 1687/10- Test procedure ⇒ ...
  • Page 348 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect charge air system tester -V.A.G 1687- to adapter -1687/10- as shown in illustration. – Connect compressed air hose -1- (compressed air supply) to charge air system tester -V.A.G 1687-.

  • Page 349: Checking Charge Pressure Control

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking charge pressure control Special tools and workshop equipment required ◆ Hand vacuum pump with accessories -V.A.G 1390- Test prerequisites ● Engine running at idling speed ●...

  • Page 350: Connection For Vacuum Hoses

    ⇒  P age – Turbocharger defective; renew turbocharger 326, Removing and installing turbocharger. Connection for vacuum hoses ⇒  P age Engine codes CJDA, CJDD 335. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 336. ⇒  P age 338...

  • Page 351: Engine Codes Cjda, Cjdd

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.3.1 Engine codes CJDA, CJDD 1 - Air mass meter -G70- 2 - Turbocharger q With vacuum unit q With position sender for charge pressure positioner -G581- 3 - Air filter q Optional 4 - Charge pressure con-...

  • Page 352: Engine Codes Cpya, Cpyb, Cpyc, Cpyd, Cpye

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.3.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - Air mass meter -G70- 2 - Turbocharger q With vacuum unit q With position sender for charge pressure positioner -G581- 3 - Charge pressure con- trol solenoid valve -N75-...

  • Page 353: Intake System, Installation Position

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ing away from engine", as shown in illustration). The markings on the air mass meter as well as on the elbow of the intake connecting pipe allow for a proper alignment when installing. 1 - ...

  • Page 354: Testing Vacuum System

    Follow these instructions before starting work and while working on system. 2.4.1 Checking supply line and non-return valve (engine codes CJDA, CJDD only). Pull vacuum hose off lower connecting piece of charge pressure control solenoid valve -N75- -arrow in II-.

  • Page 355: Checking Control Line To Turbocharger, Engine Codes Cjda, Cjdd, Cpya, Cpyb, Cpyc

    – Check control line to turbocharger 339. 2.4.2 Checking control line to turbocharger, en- gine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE – Pull off vacuum hose on connecting piece of charge pres- sure control solenoid valve -N75- -1- and vacuum unit of tur- ⇒ ...

  • Page 356: Checking Vacuum Hoses

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.4.3 Checking vacuum hoses 1 - Charge pressure con- trol solenoid valve - N75- 2 - Retaining clip for vac- uum line on retainer Note The vacuum line is prefabricated. Checking components and func- tions WARNING...

  • Page 357: Markings On Air Mass Meter And On Elbow Of The Intake Connecting Pipe, View From Tur- Bocharger End

    – Marking -2- is located below marking -3- on the same level as the bracket. Checking charge pressure control sole- noid valve -N75-, engine codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE Special tools and workshop equipment required ◆...
  • Page 358 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ If the engine is idling or OFF, the activation of the valve can also be checked by touching it. ◆ During activation with the engine idling, the linkage of the charge pressure control vacuum unit on the turbocharger must move back and forth.

  • Page 359: Checking Charge Pressure Sender -G31

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Check wiring between test box and connector for open cir- cuit referring to current flow diagram. ◆ Contact 2 + socket 20 ● Cable resistance: max. 2.0 Ω. –...
  • Page 360 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note The turbocharger tester -V.A.G 1397 A- is required to provide an independent figure for comparison. The turbocharger tester must be set to range I (absolute pressure). A barometer can be used instead.

  • Page 361: Checking Position Sender For Charge Pressure Positioner -G581

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking position sender for charge pressure positioner -G581- Special tools and workshop equipment required ◆ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715- ◆ Auxiliary measuring set -V.A.G 1594D- ◆...
  • Page 362 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Engine codes CJDA, CJDD - renew position sender. ◆ Engine codes CPYA, CPYB, CPYC, CPYD, CPYE - renew complete turbocharger. Checking voltage supply Pull 3-pin connector off position sender for charge pressure po- ⇒ ...

  • Page 363: Checking Exhaust Gas Temperature Sender 1 -G235- (Exhaust Gas Temperature Sender Ahead Of Turbocharger)

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking exhaust gas temperature sender 1 -G235- (exhaust gas tempera- ture sender ahead of turbocharger) Special tools and workshop equipment required ◆ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715- ◆...
  • Page 364 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Indicated on display: Display group 100 xxx°C xxx°C xxx mbar xxx mbar – Check exhaust gas temperature value from exhaust gas temperature sender 3 -G495- (exhaust gas temperature sender ahead of diesel particulate filter) in display zone 1 and from exhaust gas temperature sender 4 -G648- (ex- haust gas temperature sensor downstream from diesel par-...
  • Page 365 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Check wiring between test box and connector for open cir- cuit referring to current flow diagram. ◆ Contact 1 + socket 89 ◆ Contact 2 + socket 9 ●...

  • Page 366: Mixture Preparation - Injection

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 23 - Mixture preparation - injection Repairing diesel direct injection system WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow-...

  • Page 367: Instructions For Working On Fuel System

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ During some checks, the engine control unit may detect and store a fault. Therefore, after completing all checks and re- pairs, interrogate the event memory and erase if necessary ⇒ ...
  • Page 368 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ If fuel system components between fuel tank and fuel high- pressure pump are removed or renewed, initial fuel filling must be carried out. ◆ If a fuel pump, fuel line (between fuel tank and fuel high- pressure pump) or the fuel filter is removed or renewed, the fuel system must be bled before the engine is started for the first time.

  • Page 369: To Avoid Any Risk Of Injuries To Persons And/Or The Destruction Of The Injection And Glow Plug System, The Following Must Be Noted

    Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Disassembling individual common high-pressure accumula- tor components is not permitted. ◆ The components should be replaced as complete units if faulty. ◆ Never attempt to bleed the common high-pressure accumu- lator system by loosening high-pressure components after starting the engine.
  • Page 370 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Observe safety precautions when work- ing on diesel direct injection fuel sys- WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions: ◆...
  • Page 371 ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 356. ⇒  P age Removing and installing intake manifold 357. 1.5.1 Engine codes CJDA, CJDD 1 - Intake manifold q Must not be disman- tled. q Removing and in- ⇒  P age 357 stalling 2 - 8 Nm...
  • Page 372 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.5.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - 8 Nm 2 - Intake manifold q Must not be disman- tled. q Removing and in- ⇒  P age 357 stalling 3 - Gasket q Renew...
  • Page 373 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.5.3 Removing and installing intake manifold Special tools and workshop equipment required ◆ Torque wrench -V.A.G 1331- ◆ Bit XZN 8 -T40159- ◆ Pliers -3314- Removing Caution Make sure that no wiring connections are damaged when...
  • Page 374 – Carefully pull connector in -direction of arrow- off glow plug. – Pull fuel return lines off fuel rail, injectors and high-pressure pump. Engine codes CJDA, CJDD – Unscrew securing bolt -arrow- and remove fuel return line. Continuation for all engine codes –...
  • Page 375 ⇒  P age 383. (It is important not to allow the high- pressure pump to run while still empty.) 1.6.1 Fuel system, engine codes CJDA, CJDD 1 - Fuel tank 2 - Fuel filter q With pre-heating valve.
  • Page 376 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age 377 q Checking return flow rate ⇒  P age q Removing and installing 377. 9 - Fuel rail 10 - Fuel pressure sender -G247- ⇒  P age q Removing and installing 379.
  • Page 377 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.6.2 Fuel system, engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - Fuel tank 2 - Fuel filter q With pre-heating valve. q Assembly overview - fuel filter ⇒  P age 304.
  • Page 378 Protect open fuel connections from dirt entrainment using suitable methods under all circumstances. ⇒  P age Engine codes CJDA, CJDD 363. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 366.
  • Page 379 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.7.1 Engine codes CJDA, CJDD 1 - 8 Nm 2 - High-pressure line, 28 q Between high-pres- sure pump and fuel rail. 3 - Fuel return lines q With pressure reten-...
  • Page 380 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 9 - High-pressure pump ⇒  P age 380 q Removing and installing 10 - 20 Nm +180° (1/2 turn) further q Renew 11 - 20 Nm +45° (1/8 turn) further q Renew 12 - Fuel pressure sender -G247-, 100 Nm ⇒ ...
  • Page 381 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Differences on fuel return line -A-, no riffled section: use clamp according to ⇒  ETKA (Elec- tronic Parts Catalogue) to connect overflow oil line. -B-, with riffled section: DO NOT use a clamp to connect over- flow oil line.
  • Page 382 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.7.2 Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 1 - High-pressure line q 30 Nm q Between high-pres- sure accumulator (fuel rail) and injec- tors (piezo injec- tors).
  • Page 383 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 7 - Copper washer q Renew 8 - O-ring q Renew 9 - Clamping plates One clamping plate encompasses 2 injectors each. q Reusable. 10 - Bolt, turn 8 Nm +270° (3/4 turn) further q Renew Note If replacement engine is fitted, it is essential to check torque.
  • Page 384 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 16 - High-pressure fuel pump q With fuel metering valve -N290- (must not be opened). q After renewing, initial fuel filling must be carried out (never allow the pump to run while it is still empty) ⇒ ...
  • Page 385 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking for injectors sticking open WARNING ◆ Always read rules for cleanliness and instructions for ⇒  P age working on fuel system 354. ◆ Always follow these rules for cleanliness and instruc- tions before starting work and while working on the fuel system.
  • Page 386 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Use hand-operated vacuum pump -VAS 6213- to generate a partial vacuum of approx. -500 mbar. If injector is OK, pressure remains constant for 30 s. If injectors are defective, the pressure drops within 2 ...
  • Page 387 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.10.1 Removing WARNING ◆ Always read rules for cleanliness and instructions for ⇒  P age working on fuel system 354. ◆ Always follow these rules for cleanliness and instruc- tions before starting work and while working on the fuel system.
  • Page 388 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Check catches Caution ● Carefully pull fuel return lines upwards vertically when disconnecting, as the 4 catches -arrow- can fracture. ● After disconnecting, check the 4 catches -arrow- to see whether they are fractured or have broken off.
  • Page 389 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.10.2 Installing Important instructions for installing injectors ● When removing and installing or renewing an injector, al- ways renew the following components and seals/O-rings: “clamping piece”, “copper seal”, “O-ring for injector bore” and “O-ring for injector return connection”.
  • Page 390 – To avoid damaging O-ring, carefully slide new, oiled O-ring onto fuel return connection. Engine codes CJDA, CJDD Caution When removing securing nuts from injector there is a risk that the relevant nut will fall into the cylinder head. Proceed very carefully to prevent unnecessary dismantling or fur- ther damage.
  • Page 391 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – After completing the repair, road-test the vehicle over a dis- tance of at least 20 km. Accelerate with full throttle at least once. Then inspect the high-pressure section of the fuel sys- tem again for leaks.
  • Page 392 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Tighten union nuts on injection line hand-tight without any tool to start with. Ensure that line correctly gets into its seat. – If necessary, proceed in the same way with other injection lines.
  • Page 393 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1.11 Checking return flow rate from fuel pressure regulating valve -N276- WARNING ◆ Always read rules for cleanliness and instructions for ⇒  P age working on fuel system 354.
  • Page 394 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Caution Always read rules for cleanliness and instructions for ⇒  P age working on fuel system 354. Follow these instructions before starting work and while working on the fuel system.
  • Page 395 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – After installation, run engine at moderate speed for several minutes and then switch off. ⇒  P age – Check fuel system for leaks 384. –...
  • Page 396 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note Seal off fuel rail bore immediately with a suitable plug to prevent dirt from entering. Installing Note ◆ Check that sealing surfaces (deformable sealing lip) and threads on fuel pressure sender -G247- are undamaged.
  • Page 397 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Counterhold -T10051- ◆ Puller -T40064- with T40064/1 ◆ Torque wrench -V.A.G 1331- ◆ Pliers -3314- Removing – Remove toothed belt from camshaft and high-pressure ⇒ ...
  • Page 398 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Disconnect connector -1- and remove bolts -arrows-. Caution Make sure that no wiring connections are damaged when disconnecting the connectors. Otherwise the whole wiring harness will need to be renewed.
  • Page 399 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Counterhold hub of high-pressure pump using counterhold -T10051- and unscrew securing nut -1-. – Fit puller -T40064- with thrust piece -T40064/1- and pin -T40064/2- as shown in illustration, and pull hub off high- pressure pump.
  • Page 400 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Caution After installation, the high pressure pump must be filled with fuel before the engine is started the 1st time (the pump must NOT be allowed to run while still empty). Note ◆...
  • Page 401 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Run engine at idling speed for several minutes - do not press accelerator - and then switch engine off again. (Fuel system bleeds itself). –...
  • Page 402 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Tester for fuel return system -6330- WARNING ◆ Always read rules for cleanliness and instructions for ⇒  P age working on fuel system 354.
  • Page 403 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note Adhere strictly to rules of cleanliness. No dirt must be allowed to get into the disconnected fuel return lines or the open connec- tions on the injectors under any circumstances. –...
  • Page 404 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking fuel metering valve -N290- Special tools and workshop equipment required ◆ K-Jetronic pressure tester -V.A.G 1318- ◆ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715- ◆...
  • Page 405 Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 difference between the pressure in display zone 2 and display zone 3 must not exceed 40 bar. Engine codes CJDA, CJDD ● Display zone 2, pressure in high pressure fuel system (specified): 170... 350 bar.
  • Page 406 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to sender contacts 1 + 2 using test leads from auxiliary measuring set -V.A.G 1594D- to measure re- sistance. Specification: 2.0...5.0 Ω If the specification is not attained: –...
  • Page 407 3 should be roughly within the same range, but they should not always be the same. The difference between the pressure in display zone 2 and display zone 3 must not exceed 40 bar. Engine codes CJDA, CJDD 2 Checking components and functions...
  • Page 408 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● Display zone 2, pressure in high pressure fuel system (specified): 170... 350 bar. ● Display zone 3, pressure in high pressure fuel system (ac- tual): 170...
  • Page 409 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to sender contacts 1 + 2 using test leads from auxiliary measuring set -V.A.G 1594D- to measure re- sistance. Specification: 3.0...6.0 Ω If the specification is not attained: –...
  • Page 410 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Checking fuel pressure sender -G247- Special tools and workshop equipment required ◆ K-Jetronic pressure tester -V.A.G 1318- ◆ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715- ◆...
  • Page 411 The difference between the pressure in display zone 2 and display zone 3 must not exceed 40 bar. Engine codes CJDA, CJDD ● Display zone 2, pressure in high pressure fuel system (specified): 170... 350 bar.
  • Page 412 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Pull fuel supply line -arrow- off high-pressure pump. – Using a suitable adapter -2-, connect K-Jetronic pressure tester -V.A.G 1318- to fuel supply line -1-. Connect other adapter -3- of K-Jetronic pressure tester -V.A.G 1318- to open connection on high-pressure pump.
  • Page 413 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 The fuel rail pressure specification in display zone 2 and the ac- tual fuel rail pressure in display zone 3 should be roughly within the same range, but they should not always be the same. The difference between the pressure in display zone 2 and display zone 3 must not exceed 40 bar.
  • Page 414 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age – Check the fuel pump 314. If no fault was detected: ⇒  P age – Check fuel pump relay -J17- 486, current flow dia- grams.
  • Page 415 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Test box -V.A.G 1598/42- with adapter cable -V.A.G 1598/39-1- ◆ Current flow diagram Note Instead of the vehicle diagnosis, testing and information system other diagnosis systems, such as the DiagRA, may be used as well.
  • Page 416 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Then, read event memory of engine control unit, and clear ⇒  P age event memory if necessary 26, read event memory. If specification is attained: Checking wiring –...
  • Page 417 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ The engine speed sender can be diagnosed via the engine control unit. ◆ During diagnosis, the engine must run at idling speed. Only "Ignition ON"...
  • Page 418 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – To do this, connect an oscilloscope, and check engine speed sender -G28- with a signal voltage of 0 - 5 V. The sender must provide an approximate square wave signal. –...
  • Page 419 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Renew engine speed sender -G28-⇒  P age 178. – Then, read event memory of engine control unit, and clear ⇒  P age event memory if necessary 26, read event memory.
  • Page 420 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to contacts 1 + 3 of connector using test leads from -V.A.G 1594- to measure voltage. – Switch on ignition. Specification: at least 4.8... 5.2 V –...
  • Page 421 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● All electrical consumers must be switched off. ● Earth connections OK Test procedure Note ◆ The intake air temperature sender -G42- and charge pres- sure sender -G31- are installed in one common housing in the charge air pipe.
  • Page 422 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to contacts 1 + 2 of sender using test leads from -V.A.G 1594- to measure resistance. Scale -A- shows resistance values for a temperature range of 0…50°C, and scale -B- shows the values for a temperature range of 50…100°C.
  • Page 423 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 If no wiring fault is detected and voltage was present between contacts 1 + 3: – Renew intake air temperature sender -G42- together with charge pressure sender -G31-. If no wiring fault is detected and no voltage was present be- tween contacts 1 + 3: –...
  • Page 424 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Check coolant temperature value in display zone 4. The temperature value must Increase uniformly and without inter- ruption. Note If there is a fault the fuel temperature will be displayed as a sub- stitute value (display zone 1).
  • Page 425 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Scale -A- shows resistance values for a temperature range of 0…50°C, and scale -B- shows the values for a temperature range of 50…100°C. Examples: ◆ 30°C is on scale -A- and corresponds to a resistance of 1500…2000 Ω.
  • Page 426 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● No air in fuel system Test procedure Note Only gold-plated contacts may be used when repairing the con- tacts in the connectors of the fuel temperature sender. –...
  • Page 427 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to sender contacts using test leads from -V.A.G 1594- to measure resistance. Scale -A- shows resistance values for a temperature range of 0…50°C, and scale -B- shows the values for a temperature range of 50…100°C.
  • Page 428 Note Only gold-plated contacts may be used when repairing contacts in connector of air mass meter. Checking voltage supply, engine codes CJDA, CJDD – Pull 5-pin connector -6- off air mass meter -G70-. – Switch on ignition. Repair Group 23 - Mixture preparation - injection...
  • Page 429 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to following connector contacts and en- gine earth using test leads from -V.A.G 1594-. ◆ Contact 5 + engine earth ● Specification: at least 11.5 V –...
  • Page 430 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to following connector contacts and en- gine earth using test leads from -V.A.G 1594-. ◆ Contact 4 + engine earth ● Specification: at least 11.5 V –...
  • Page 431 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ The throttle valve module -J338- and throttle valve potenti- ometer -G69- are installed in one common housing. ◆ Only gold-plated contacts may be used when repairing con- tacts in connector of throttle valve module -J338-.
  • Page 432 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Check wiring between test box and connector for open cir- cuit referring to current flow diagram. ◆ Contact 1 + socket 25 ◆ Contact 2 + socket 41 ◆...
  • Page 433 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age Checking data bus 424. Checking voltage supply for engine control unit Special tools and workshop equipment required ◆ Hand multimeter -V.A.G 1526- or multimeter -V.A.G 1715- ◆...
  • Page 434 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age – Check terminal 30 voltage supply relay -J317- 486, current flow diagrams. – Check cable connections for open circuit, short circuit and transfer resistance at contacts referring to current flow dia- gram.
  • Page 435 – Activated charcoal filter solenoid valve 579. – Throttle valve 12867. – Or perform an automatic test of all final controls. Engine codes CJDA, CJDD – Set the mileage which has been read beforehand in new en- ⇒  P age gine control unit 460, check diesel particulate filter.
  • Page 436 The display zones may be shown one below the other or next to each other on the display of the vehicle diagnostic tester. – Check specifications in display zones 3 and 4. Engine codes CJDA, CJDD ● Specification in display zone 3: -70...+70 mbar ● Specification in display zone 4: -15...+15 mbar Engine codes CPYA, CPYB, CPYC, CPYD, CPYE ●...
  • Page 437 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 If the specifications are again not attained: – If necessary, renew exhaust gas pressure sensor 1 -G450- ⇒  P age 427, Assembly overview - diesel particulate filter. Reading injector delivery calibration values/injector voltage calibration val- ues, and storing them in engine control...
  • Page 438 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● “Channel number 74” for injector 4 -N33- – Press field. Keyboard – Use the on-screen keyboard to enter the 7-digit injector de- livery calibration values/injector voltage calibration values for the respective injector.
  • Page 439 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Adapting engine control unit -J623- to exhaust gas recirculation valve Note ◆ If the exhaust gas recirculation valve has been renewed, it must be adapted. ◆...
  • Page 440 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● Earth connections OK ● All electrical consumers must be switched off. Procedure – Select diagnosis function “014-Long adaptation”. The ignition must be switched on for this purpose. –...
  • Page 441 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Test procedure – Pull 94-pin connector off engine control unit -J623-. – Using adapter cable -V.A.G 1598/39-2-, connect test box -V.A.G 1598/42- to engine control unit and to -connections A and B- of test box.
  • Page 442 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 26 - Exhaust system Removing and installing parts of exhaust system WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow-...
  • Page 443 ⇒  P age Engine codes CJDA, CJDD 427. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 428. 1.1.1 Engine codes CJDA, CJDD 1 - Exhaust gas pressure sensor 1 -G450- q Checking ⇒  P age 446 2 - 10 Nm 3 - Shield 4 - Lambda probe -G39-...
  • Page 444 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age 444 q Checking 9 - 25 Nm 10 - Bracket q Bolted to cylinder block. 11 - 25 Nm 12 - Diesel particulate filter q With oxidising catalytic converter ⇒  P age 460 q Check diesel particulate filter q After diesel particulate filter has been renewed, adaptation value for ash deposit mass must be set to ⇒ ...
  • Page 445 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - Lambda probe -G39- q 50 Nm q Grease only the threads with high- temperature paste G 052 112 A3; high- temperature paste -G 052 112 A3- must not get into the slots of probe body.
  • Page 446 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 10 - Bracket q Or no. 14 installed 11 - 25 Nm 12 - 25 Nm 13 - 25 Nm 14 - Bracket q Or no. 9 installed 15 - Bracket q Or no. 9 installed 16 - Clamp ahead of oxidising catalytic converter, 7 Nm q Make sure it is firmly seated q Note installation position 17 - Seal...
  • Page 447 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Detach connectors from exhaust gas temperature senders. – Disconnect connector of lambda probe -2-. – Remove lambda probe -2- and exhaust gas temperature senders. –...
  • Page 448 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ Diesel particulate filter and bracket must still be free to move. ◆ Install to engine in reverse order of removal. Tightening sequence: 1  - Tighten clamp -1- to 7 Nm. 2 - Tighten bolt -5- to 23 Nm.
  • Page 449 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ The threaded connection is accessible from below. – Unscrew exhaust temperature sender 1 -G235- -item 1- from exhaust manifold. Installing ⇒  I tem 21 on page ●...
  • Page 450 – Observe rules for cleanliness 354. ⇒  P age Engine codes CJDA, CJDD 434. ⇒  P age Engine codes CPYA, CPYB, CPYC, CPYD, CPYE 435. 2.1.1 Engine codes CJDA, CJDD 1 - Gasket q Renew q Note installation po- sition 2 - Connecting pipe Caution Ensure that decou-...
  • Page 451 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.1.2 Engine codes CPYA, CPYB, CPYC, CPXD, CPYE 1 - 9 Nm 2 - Exhaust gas recircu- lation pipe q With flexible joint; do not bend flexible joint - danger of cracking.
  • Page 452 ⇒  P age 444. ⇒  P age Checking exhaust gas pressure sensor 1 -G450- 446. Check diesel particulate filter, engine codes CJDA, CJDD ⇒  P age 460. Regeneration of diesel particulate filter, engine codes CJDA, ⇒  P age CJDD 463.
  • Page 453 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 vating the exhaust gas recirculation valve -N18- in a synchron- ised manner, so that the extreme values for the exhaust gas re- circulation system can be read in the measured value block. Test prerequisites ●...
  • Page 454 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Current flow diagram Test prerequisites ● Fuses must be OK. ● The battery voltage must be at least 11.5 V. ● All electrical consumers must be switched off. ●...
  • Page 455 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to following connector contacts and en- gine earth using test leads from -V.A.G 1594-. ◆ Contact 1 + engine earth ◆ Contact 1 + contact 3 ●...
  • Page 456 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Current flow diagram Test prerequisites ● Fuses must be OK. ● The battery voltage must be at least 11.5 V. ● All electrical consumers must be switched off. ●...
  • Page 457 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Then, read event memory of engine control unit, and clear ⇒  P age event memory if necessary 26, read event memory. If no wiring fault is detected and no voltage was present be- tween contacts 2 + 6: ⇒ ...
  • Page 458 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect multimeter to connector contact 4 and engine earth using test leads from -V.A.G 1594- to measure voltage. – Switch on ignition. Specification: at least 11.5 V –...
  • Page 459 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note Only gold-plated contacts may be used when repairing the con- tacts in the connectors of the exhaust gas temperature sender – Connect vehicle diagnostic tester, and select engine control ⇒ ...
  • Page 460 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Exit diagnosis function. – Switch off ignition. Checking resistance – Disconnect 2-pin connector from exhaust gas temperature ⇒  P age sender 3 -G495- 427. –...
  • Page 461 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ● All electrical consumers must be switched off. ● Earth connections OK ● Engine must be cold Test procedure Note Only gold-plated contacts may be used when repairing the con- tacts in the connectors of the exhaust gas temperature sender –...
  • Page 462 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – If the value in display zone 2 of display group 100 is higher than the value in display field 1, the two senders have been interchanged.
  • Page 463 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Current flow diagram Test prerequisites ● Fuses must be OK. ● The battery voltage must be at least 11.5 V. ● All electrical consumers must be switched off. ●...
  • Page 464 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Pull3-pin connector -1- off exhaust pressure sensor 1 -G450-. – Connect multimeter to contacts 1 + 2 of connector using test leads from -V.A.G 1594- to measure voltage. –...
  • Page 465 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ⇒  P age – Renew engine control unit -J623- 418. Renewing vacuum unit with position sender for charge pressure positioner - G581- Special tools and workshop equipment required ◆...
  • Page 466 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Seal opening in turbocharger with the sealing cap from the spare-parts kit. – Pull off vacuum line at turbocharger. – Unscrew securing nut -arrow- where the oil supply line/vac- uum line is connected to the cylinder head.
  • Page 467 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ A = 57 mm – Fit ring spanner -T10423- -1- and socket AF 10 mm -T10422- -2- with reversible ratchet -3-, as shown in illustra- tion.
  • Page 468 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Tighten securing bolts -arrows- to 8 Nm. Note Make sure that the guide is free to move along the control rod. – Remove protective cap, fit oil supply line to turbocharger, and tighten it to 22 Nm.
  • Page 469 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Fit socket inset -T10422-, counterhold locknut -B- with ring spanner -T10423- and tighten securing nut -A-. Caution Cause a partial vacuum of 0.75 ± 0.05 bar to act on the vac- uum unit to ensure that the adjusting lever rests against the stop.
  • Page 470 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Click the "Activate" button in the lower half of the screen. – Observe value in lower part of screen. It must fluctuate be- tween 0.65 ... 0.85 V and 3.30 ... 3.90 V (vacuum unit travels to both end stops alternately).
  • Page 471 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Evaluating filter status – Connect vehicle diagnostic tester, and select engine control ⇒  P age 23 unit. – Select diagnosis function “011-Read measured value block”. The ignition must be switched on.
  • Page 472 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 WARNING During a regeneration the diesel particulate filter be- comes very hot - risk of fire. ◆ Place the vehicle/machine in such a way that the die- sel particulate filter does not get in contact with dry grass or any other flammable materials.
  • Page 473 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Note ◆ During regeneration the values in the display zones 2 and 3 should decrease. ◆ The two values may decrease down to 0, and the regenera- tion may still continue.
  • Page 474 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Press button 3 times to go back to diagnosis function ← menu. Select diagnosis function “014-Long adaptation”. – Select “Channel number 14”. – Klick on Keyboard –...
  • Page 475 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Press button to reset the learnt value. Confirm Note ◆ The engine speed is now increased automatically and the adaptation starts. ◆ The adaptation takes approx. 30 seconds. –...
  • Page 476 – Switch off ignition. – Adapt exhaust gas pressure sensor 1 -G450-. 3.10 Checking diesel particulate filter, en- gine codes CJDA, CJDD Note ◆ If the diesel particulate filter is renewed, the adaptation value for the ash deposit mass must be set to “0”, renew diesel particulate filter.
  • Page 477 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Connect vehicle diagnostic tester, and select engine control ⇒  P age 23 unit. – Select diagnosis function “011-Read measured value block”. – Select “Display group 106”. Indicated on display: Display group 106 ----...
  • Page 478 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 DANGER! If the soot loading in the display zones 2 and 3 exceeds 40 g, NEVER start a regeneration! Risk of fire. If soot loading in display zones 2 and 3 is between 30.0 ... 37 g: –...
  • Page 479 – Switch off ignition. – Renew diesel particulate filter. 3.12 Regeneration of diesel particulate filter, engine codes CJDA, CJDD Note ◆ A regeneration of the diesel particulate filter can only be per- formed if the coolant temperature is at least 80°C and the exhaust gas temperature ahead of the diesel particulate filter is at least 161°C.
  • Page 480 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Start service regeneration as follows: – Press button (back) twice. ← Select diagnosis function “015-Access permissions”. – Enter following access code: ● Access code: 40809 –...
  • Page 481 ⇒  P age event memory if necessary 26, read event memory. 3.13 Renewing diesel particulate filter, en- gine codes CJDA, CJDD ⇒  P age – Renew diesel particulate filter 427. If the diesel particulate filter has been renewed, the adaptation value for the ash deposit mass must be set to “0”...
  • Page 482 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 cludes the ash deposit mass and the operating time of the die- sel particulate filter. However, based on the mileage or the oper- ating hours since the last change of the diesel particulate filter this data can be restored approximately.
  • Page 483 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 27 - Starter, current supply, CCS Starter -B- WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! ⇒ ...
  • Page 484 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Test procedure – Connect multimeter between terminal 50 -2- (with connector connected) and battery earth/engine earth to measure volt- age. – Operate ignition/starter switch, and check the voltage supply. Specification: at least 8.0 V If there is voltage on terminal 50 -2- on solenoid switch: –...
  • Page 485 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Clean connections on starter and earth strap between en- gine and power unit. Do not disconnect earth strap from power unit when doing this. –...
  • Page 486 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unbolt positive wire of terminal 30 -1-, and disconnect con- nector of terminal 50 -2-. – Unbolt earth wire from securing bolt of starter -arrow-. –...
  • Page 487 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew securing bolt of starter -arrow-. – Remove starter downwards. 1.4.2 Installing Install in reverse order. In the process, note the following: – Tighten threaded connections to specified torque ⇒ ...
  • Page 488 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Assembly overview - alternator -C- Note ⇒  P age Removing and installing bracket for ancillary units 144. Repair Group 27 - Starter, current supply, CCS...
  • Page 489 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 1 - Hexagon bolt with washer and threaded element, 2 Nm q M4 x 20 q M4 x 15 2 - Protective cap q For alternator 3 - Phillips head screw, 2 Nm q M4 x 20 4 - Protective cap...
  • Page 490 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Attachment of “battery positive wire” to alternator Special tools and workshop equipment required ◆ Torque wrench (5…50 Nm) -V.A.G 1331- Note The threaded connection for the positive wire on the alternator is labelled with “B1+”.
  • Page 491 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Unscrew securing nuts -arrows A- and securing bolt -arrow B- of protective cap, and remove protective cap. – Switch on multimeter -V.A.G 1715-. – Connect black measuring cable (-) to battery earth strap. –...
  • Page 492 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.3.1 Removing Note ◆ The procedure described below provides only general in- structions for removing and installing the alternator, since due to the various use cases it is not possible to specify a common procedure.
  • Page 493 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.3.2 Installing Install in reverse order. In the process, note the following: – To prevent any damage to the cylinder block and ancillary bracket, always adhere to the tightening sequence and ⇒ ...
  • Page 494 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.4.1 Removing and installing voltage regulator -C1-, Bosch Special tools and workshop equipment required ◆ Torque screwdriver (1…5 Nm) -V.A.G 1624- ⇒  P age Removing 478.
  • Page 495 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Install protective cap, and tighten securing nuts -arrows A- and securing bolt -arrow B- to 25 Nm. ⇒  P age – Install alternator -C- 475.
  • Page 496 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Release locking lugs -arrows-, and pull protective cap off voltage regulator. – Push carbon brushes into housing of voltage regulator, and insert voltage regulator in alternator. –...
  • Page 497 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.1 Removing and installing poly V-belt pulley without freewheel Special tools and workshop equipment required ◆ Torque wrench (40…200 Nm) -V.A.G 1332- ◆ Socket 24 mm -3310- ⇒ ...
  • Page 498 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.2 Removing and installing poly V-belt pulley with freewheel, Bosch Special tools and workshop equipment required ◆ Torque wrench (40…200 Nm) -V.A.G 1332- ◆ Adapter -3400- ⇒ ...
  • Page 499 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Release socket drive -1- and pull off grip -2-. – Turn grip -2- of torque wrench through 180 degrees, and re- insert socket drive. –...
  • Page 500 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 2.5.3 Removing and installing poly V-belt pulley with freewheel, Valeo Special tools and workshop equipment required ◆ Adapter -3400- ◆ Torque wrench (40… 200 Nm) -V.A.G 1332- ◆...
  • Page 501 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Insert TORX key -V.A.G 1603/1- in alternator shaft. – Loosen threaded connection by turning clockwise. Counter- hold with ring spanner when doing this. – Hold poly V-belt pulley with freewheel by hand. Turn drive shaft of alternator until poly V-belt pulley with freewheel can be removed.
  • Page 502 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Special tools and workshop equipment required ◆ Adapter -3400- Test prerequisite ● Poly V-belt tension OK and alternator secured properly Test procedure – Remove protective cap from poly V-belt pulley with free- wheel.
  • Page 503 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 ◆ Vehicles/machines compliant with emission standard (EU 5), ⇒  P age engine codes CJDA, CJDD 517. Current flow diagrams, engine codes CPYA, CPYB, compliant with emission...
  • Page 504 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses A - Battery B - Starter C - Alternator C1 - Voltage regulator D - Ignition/starter switch S5 - Fuse q 15 A q In fuse holder S8 - Fuse q 5 A q In fuse holder S10 - Fuse...
  • Page 505 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump J49 - Electric fuel pump 2 relay J179 - Automatic glow period control unit Q10 - Glow plug 1 Q11 - Glow plug 2 Q12 - Glow plug 3...
  • Page 506 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.3 Terminal 30 voltage supply relay, engine control unit, fuses J317 - Terminal 30 volt- age supply relay J623 - Engine control unit S2 - Fuse q 20 A q In fuse holder S4 - Fuse q 15 A q In fuse holder...
  • Page 507 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.4 Jumpers, charge pressure sender, intake air temperature sender, air mass me- ter, engine control unit G31 - Charge air pres- sure sender G42 - Intake air tempera- ture sender G70 - Air mass meter J623 - Engine control unit...
  • Page 508 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.5 Accelerator position sender, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4 G79 - Accelerator posi- tion sender G185 - Accelerator posi- tion sender 2 J623 - Engine control unit N30 - Injector, cylinder 1...
  • Page 509 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve G40 - Hall sender G62 - Coolant tempera- ture sender J623 - Engine control unit N276 - Fuel pressure reg- ulating valve N290 - Fuel metering...
  • Page 510 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit G28 - Engine speed sender G69 - Throttle valve po- tentiometer G81 - Fuel temperature...
  • Page 511 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.8 Exhaust gas recirculation potentiometer, exhaust gas temperature sender 1, fuel pressure sender, engine control unit, exhaust gas recirculation valve G212 - Exhaust gas recir- culation potentiome- G235 - Exhaust gas tem- perature sender 1 G247 - Fuel pressure...
  • Page 512 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.9 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather F - Brake light switch F47 - Brake pedal switch q * Safety circuit J67 - Brake system check blocking diode...
  • Page 513 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.10 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit E261 - Working speed governor switch E426 - Working speed control, resume but- E433 - Preset speed 1...
  • Page 514 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.11 Preset speed switch 3, engine control unit, alternator warning lamp, glow pe- riod warning lamp, exhaust emissions warning lamp E435 - Preset speed 3 switch J623 - Engine control unit K2 - Warning lamp for al- ternator...
  • Page 515 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.12 Working speed control, safety contact switch, working speed control, de- crease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp E427 - Working speed control, safety con- tact switch...
  • Page 516 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.13 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radi- ator fan J26 - Radiator fan relay J623 - Engine control unit S... - Fuse q 5 A q In fuse holder S42 - Radiator fan single fuse...
  • Page 517 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.1.14 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp F1 - Oil pressure switch J150 - Oil pressure moni- tor delay relay q * Customer-specific J623 - Engine control unit K3 - Oil pressure warn-...
  • Page 518 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve ⇒  P age 507. Engine speed sender, throttle valve potentiometer, fuel temper- ature sender, position sender for charge pressure positioner, ⇒ ...
  • Page 519 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses A - Battery B - Starter C - Alternator C1 - Voltage regulator D - Ignition/starter switch S5 - Fuse q 15 A q In fuse holder S8 - Fuse q 5 A q In fuse holder S10 - Fuse...
  • Page 520 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump J49 - Electric fuel pump 2 relay J179 - Automatic glow period control unit Q10 - Glow plug 1 Q11 - Glow plug 2 Q12 - Glow plug 3...
  • Page 521 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.3 Terminal 30 voltage supply relay, engine control unit, fuses J317 - Terminal 30 volt- age supply relay J623 - Engine control unit S2 - Fuse q 20 A q In fuse holder S4 - Fuse q 15 A q In fuse holder...
  • Page 522 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.4 Jumpers, charge pressure sender, intake air temperature sender, air mass me- ter, engine control unit G31 - Charge air pres- sure sender G42 - Intake air tempera- ture sender G70 - Air mass meter J623 - Engine control unit...
  • Page 523 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve G40 - Hall sender G62 - Coolant tempera- ture sender J623 - Engine control unit N276 - Fuel pressure reg- ulating valve N290 - Fuel metering...
  • Page 524 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit G28 - Engine speed sender G69 - Throttle valve po- tentiometer G81 - Fuel temperature...
  • Page 525 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.8 Exhaust gas recirculation potentiometer, fuel pressure sender, engine control unit, exhaust gas recirculation valve G212 - Exhaust gas recir- culation potentiome- G247 - Fuel pressure sender J623 - Engine control unit N18 - Exhaust gas recir- culation valve...
  • Page 526 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.9 Exhaust gas temperature sender 1, exhaust gas temperature sender 3, ex- haust gas temperature sender 4, engine control unit G235 - Exhaust gas tem- perature sender 1 G495 - Exhaust gas tem- perature sender 3 G648 - Exhaust gas tem-...
  • Page 527 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.10 Lambda probe, exhaust gas pressure sensor 1, engine control unit, lambda probe heater G39 - Lambda probe G450 - Exhaust gas pres- sure sensor 1 J623 - Engine control unit Z19 - Lambda probe heater T6b - 6-pin connector...
  • Page 528 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.11 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather F - Brake light switch F47 - Brake pedal switch q * Safety circuit J67 - Brake system check blocking diode...
  • Page 529 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.12 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit E261 - Working speed governor switch E426 - Working speed control, resume but- E433 - Preset speed 1...
  • Page 530 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.13 Preset speed 3 switch, engine control unit, alternator warning lamp, glow pe- riod warning lamp, exhaust emissions warning lamp, diesel particulate filter warning lamp E435 - Preset speed 3 switch J623 - Engine control...
  • Page 531 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.14 Working speed control, safety contact switch, working speed control, de- crease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp E427 - Working speed control, safety con- tact switch...
  • Page 532 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.2.15 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radi- ator fan J26 - Radiator fan relay J623 - Engine control unit S... - Fuse q 5 A q In fuse holder S42 - Radiator fan single fuse...
  • Page 533 T94 - 94-pin connector * - Customer-specific ** - Speed signal output B-M - Battery earth/en- gine earth Current flow diagrams, engine codes CJDA, CJDD, compliant with emission standard (EU5) Battery, starter, alternator, voltage regulator, ignition/starter ⇒  P age switch 519. Electric fuel pump 2 relay, automatic glow period control unit, ⇒ ...
  • Page 534 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve ⇒  P age 524. Engine speed sender, throttle valve potentiometer, fuel temper- ature sender, position sender for charge pressure positioner, ⇒ ...
  • Page 535 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.1 Battery, starter, alternator, voltage regulator, ignition/starter switch fuses A - Battery B - Starter C - Alternator C1 - Voltage regulator D - Ignition/starter switch S5 - Fuse q 15 A q In fuse holder S8 - Fuse q 5 A q In fuse holder S10 - Fuse...
  • Page 536 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.2 Electric fuel pump 2 relay, automatic glow period control unit, glow plugs, fuses, supplementary fuel pump J49 - Electric fuel pump 2 relay J179 - Automatic glow period control unit Q10 - Glow plug 1 Q11 - Glow plug 2 Q12 - Glow plug 3...
  • Page 537 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.3 Terminal 30 voltage supply relay, engine control unit, fuses J317 - Terminal 30 volt- age supply relay J623 - Engine control unit S2 - Fuse q 20 A q In fuse holder S4 - Fuse q 15 A q In fuse holder...
  • Page 538 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.4 Jumpers, charge pressure sender, intake air temperature sender, air mass me- ter, engine control unit G31 - Charge air pres- sure sender G42 - Intake air tempera- ture sender G70 - Air mass meter J623 - Engine control unit...
  • Page 539 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.5 Accelerator position sender, accelerator position sender 2, engine control unit, injectors, cylinders 1 - 4 G79 - Accelerator posi- tion sender G185 - Accelerator posi- tion sender 2 J623 - Engine control unit N30 - Injector, cylinder 1...
  • Page 540 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.6 Hall sender, coolant temperature sender, engine control unit, fuel pressure regulating valve, fuel metering valve G40 - Hall sender G62 - Coolant tempera- ture sender J623 - Engine control unit N276 - Fuel pressure reg- ulating valve N290 - Fuel metering...
  • Page 541 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.7 Engine speed sender, throttle valve potentiometer, fuel temperature sender, position sender for charge pressure positioner, throttle valve module, engine control unit G28 - Engine speed sender G69 - Throttle valve po- tentiometer G81 - Fuel temperature...
  • Page 542 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.8 Exhaust gas recirculation potentiometer, fuel pressure sender, engine control unit, exhaust gas recirculation valve G212 - Exhaust gas recir- culation potentiome- G247 - Fuel pressure sender J623 - Engine control unit N18 - Exhaust gas recir- culation valve...
  • Page 543 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.9 Exhaust gas temperature sender 1, exhaust gas temperature sender 3, ex- haust gas temperature sender 4, engine control unit G235 - Exhaust gas tem- perature sender 1 G495 - Exhaust gas tem- perature sender 3 G648 - Exhaust gas tem-...
  • Page 544 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.10 Lambda probe, exhaust gas pressure sensor 1, engine control unit, lambda probe heater G39 - Lambda probe G450 - Exhaust gas pres- sure sensor 1 J623 - Engine control unit Z19 - Lambda probe heater T6b - 6-pin connector...
  • Page 545 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.11 Brake light switch, brake pedal switch, engine control unit, charge pressure control solenoid valve, heater element for crankcase breather F - Brake light switch F47 - Brake pedal switch q * Safety circuit J67 - Brake system check blocking diode...
  • Page 546 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.12 Working speed control switch, working speed control, resume button, preset speed switch 1 and 2, clutch pedal switch, engine control unit E261 - Working speed governor switch E426 - Working speed control, resume but- E433 - Preset speed 1...
  • Page 547 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.13 Preset speed 3 switch, engine control unit, alternator warning lamp, glow pe- riod warning lamp, exhaust emissions warning lamp, diesel particulate filter warning lamp E435 - Preset speed 3 switch J623 - Engine control...
  • Page 548 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.14 Working speed control, safety contact switch, working speed control, de- crease speed button, working speed control, increase speed button, working speed control switch 2, engine control unit, working speed warning lamp E427 - Working speed control, safety con- tact switch...
  • Page 549 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.15 Jumpers, radiator fan relay, engine control unit, radiator fan single fuse, radi- ator fan J26 - Radiator fan relay J623 - Engine control unit S... - Fuse q 5 A q In fuse holder S42 - Radiator fan single fuse...
  • Page 550 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 3.3.16 Diagnostic connection, oil pressure switch, engine control unit, oil pressure warning lamp F1 - Oil pressure switch J150 - Oil pressure moni- tor delay relay q * Customer-specific J623 - Engine control unit K3 - Oil pressure warn-...
  • Page 551 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 28 - Glow plug system Glow plug system WARNING Adhere to the general safety regulations and the notes on ⇒  P age 1 repair work on the engine! WARNING When doing any repair work, pay attention to the follow- ing due to the cramped conditions:...
  • Page 552 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 Removing, installing and checking glow plugs Special tools and workshop equipment required ◆ Jointed spanner -3220- ◆ Pliers -3314- ◆ Torque wrench (5…50 Nm) -V.A.G 1331- ◆...
  • Page 553 Industriemotoren - Industrial Engines 2009 ▶ Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA 189) 05.2015 – Position pliers -3314- with groove -arrow A- on support sleeve shoulder -arrow B- and pull plugs off glow pin plugs. – Carefully pull connector off glow plug in direction of -arrow-. –...

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