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CPYA
Workshop manual
Volkswagen CPYA Workshop Manual
Industrial engine
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Technical Data
Description of Symbols
Important Notes for Repair Work on the Engine
General Safety Notes
Technical Data
Engine Number/Engine Code
Engine Data
Service Work
Entries in Service History Book
Service Intervals
Countries with High Sulphur Content in Diesel Fuel
Severe Operating Conditions
Extended Service Intervals
Scope of Interval Service
General Scopes of Service
Additional Work
Scopes of Service for Gas Systems
Descriptions of Work, Engine, General
Engine and Add-On Parts in Engine Compartment (from above and Below): Perform Visual Check for Leaks and Damage
Perform Road Test
Add-On Parts on the Engine Peripherals
Warranty
Repair Work - Important Information
Warranty Terms
Vehicle Self-Diagnosis
Features of Vehicle Self-Diagnosis
Technical Data of Vehicle Self-Diagnosis
Read Version of Engine Control Unit
Available Diagnosis Functions When Using the Vehicle Diagnosis, Testing and Information System
Connecting Vehicle Diagnostic Tester and Selecting Engine Control Unit
Connecting Test Box to Check Lines
Connecting Test Box -V.A.G 1598/42- Using Adapter Cable -V.A.G 1598/39-1
Connecting Test Box -V.A.G 1598/42- Using Adapter Cable -V.A.G 1598/39-2
Event Memory
Reading Event Memory
Clearing Event Memory
List of Fault Codes
Fault Code: 00022/P0016
Fault Code: 00257/P0101
Fault Code: 04110/P100E
Fault Code: 08320/P2080
Fault Code: 13256/P33C8
Fault Code: 49153/U0001
Final Control Diagnosis
Performing Final Control Diagnosis
Measured Value Blocks, Engine Codes CJDA, CJDD
Safety Precautions
Reading Measured Value Block
Evaluating Measured Value Blocks at Idling Speed
Display Group 1 - Injected Quantity
Display Group 2 - Idling Speed
Display Group 3 - Exhaust Gas Recirculation
Display Group 4 - Activation of Injectors -N30
Display Group
Display Group 7 - Temperatures
Display Group 10 - Air Quantities
Display Group 11 - Charge Pressure Control
Display Group 12 - Status
Display Group 13 - Smooth Running Control 1
Display Group 20 - Fuel Rail Values 3
Display Group 20 - Fuel Rail Values
Display Group 30 - Pedal Encoder
Display Group 34 - Charge Pressure Positioner
Display Group 99 - Exhaust Gas Temperature Sender
Display Group
Display Group 100 - Diesel Particulate Filter, Exhaust Gas Temperature Sender, Pressure Differential Sender
Display Group 106 - Diesel Particulate Filter, Regeneration 6
Display Group 108 - Diesel Particulate Filter, Regeneration 8
Evaluating Measured Value Blocks at Full Load
Conditions for Measurements at Full Load
Display Group 1 - Injected Quantity
Display Group 104
Display Group 3 - Exhaust Gas Recirculation
Display Group 8 - Torque Limit 1
Display Group 11 - Charge Pressure Control
Measured Value Blocks, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE, CPYF
Cpyg
Safety Precautions
Reading Measured Value Block
Display Group 245
Display Group
Display Group 250
Display Group 253
Display Group 254
Evaluating Measured Value Blocks at Full Load (Engine Code CPYA)
Conditions for Measurements at Full Load
Display Group 1 - Injected Quantity
Display Group 3 - Exhaust Gas Recirculation
Display Group 8 - Torque Limit 1
Display Group 11 - Charge Pressure Control
Evaluating Measured Value Blocks at Full Load (Engine Code CPYB)
Conditions for Measurements at Full Load
Display Group 1 - Injected Quantity
Display Group 3 - Exhaust Gas Recirculation
Display Group 8 - Torque Limit
Display Group 11 - Charge Pressure Control
Removing and Installing Engine
Notes on Removing
Securing Engine to Assembly Stand
Notes on Installing
Specified Torques
Additional Information and Assembly Work for Power Units with Air Conditioning System
Crankshaft Group
Dismantling and Assembling Engine
Assembly Overview - Poly V-Belt Drive, with Air Conditioner Compressor
Assembly Overview - Poly V-Belt Drive, Without Air Conditioner Compressor
Removing and Installing or Renewing Poly V-Belt
Poly V-Belt: Check Condition
Removing and Installing Poly V-Belt Tensioner, Engines with Air Conditioner Compressor Only
Removing and Installing Ancillary Bracket
Assembly Overview - Toothed Belt Drive, Engine Codes CJDA, CJDD, Without Crankshaft Seal
Removing and Installing Engine Bracket
Assembly Overview - Toothed Belt Drive, Engine Codes CPYA, CPYB, CPYC, CPYE, with Crankshaft Seal
Removing and Installing Toothed Belt Guard with Inspection Cover for Checking Tension of Toothed Belt
Performing Visual Check of Toothed Belt Tension
Assessing Wear on Tensioning Roller and Belt Pulleys
Wear of High-Pressure Pump Pulley
Assessing Wear
Removing and Installing Crankshaft Protective Cover
Assembly Overview - Crankcase, Engine Codes CJDA, CJDD
Assembly Overview - Crankcase, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Removing and Installing Sealing Flange and Flywheel
Assembly Overview - Sealing Flange, Belt Pulley End
Renewing Crankshaft Oil Seal - Pulley End
Removing
Installing
Removing and Installing Crankshaft Sealing Flange, Pulley End
Removing
Installing
Assembly Overview - Sealing Flanges and Flywheel
Renewing Crankshaft Sealing Flange - Flywheel End
Pressing out Sealing Flange with Sender Wheel
Pressing in Sealing Flange with Sender Wheel
A - Assembling Seal with Sender Wheel on Assembly Tool -T10134
B - Installing Assembly Tool -T10134- with Sealing Flange to Crankshaft Flange
C - Bolting Assembly Tool -T10134- to Crankshaft Flange
D - Pressing Sender Wheel Onto Crankshaft Flange Using Assembly Tool -T10134
E - Checking Installation Position of Sender Wheel on Crankshaft
F - Re-Pressing Sender Wheel
Removing and Installing Engine Speed Sender -G28
Removing
Installing
Removing and Installing Crankshaft
Assembly Overview - Crankshaft
Crankshaft Dimensions
Pulling Needle Bearing, if Fitted, out of and Driving into Crankshaft
Pulling out
Driving in
Dismantling and Assembling Pistons and Conrods
Assembly Overview - Pistons and Conrods
Separating New Conrods
Bearing Shells - Installation Position
Checking Piston Projection at TDC
Piston and Cylinder Dimensions
Cylinder Head, Valve Gear
Cylinder Head
Assembly Overview - Cylinder Head
Removing and Installing Hall Sender -G40
Assembly Overview - Cylinder Head Cover, Engine Codes CJDA, CJDD
Removing and Installing Cylinder Head Cover
Assembly Overview - Cylinder Head Cover, Engine Codes CPYA, CPYB, CPYC, CPYD
Cpye
Removing and Installing Cylinder Head Cover
Renewing Toothed Belt and Toothed Belt Tensioning Roller for Camshaft Drive, Engine Co- des CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE
Removing
Installing, Tensioning
Checking Compression
Removing and Installing Cylinder Head
Notes on Removing
Notes on Installing
Removing and Installing Vacuum Pump
Repairing Valve Gear
Assembly Overview - Valve Gear
Valves
Valve Dimensions
Checking Valve Guides
Renewing Valve Stem Seals
Removing and Installing Camshaft
Removing
Installing
Removing and Installing Camshaft Oil Seal
Engines up to
Engines as of
Lubrication
Engine Oil
Engine Oil Level: Check
Engine Oil: Draining or Extracting; Renewing Oil Filter and Replenishing Engine Oil
Draining or Extracting Engine Oil
Renewing Engine Oil Filter, Engine Codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD
Cpye
Replenishing Engine Oil
Parts of Lubrication System
Assembly Overview - Oil Pump, Sump
Engine Codes CJDA, CJDD
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Removing and Installing Sump
Removing
Installing
Oil Filter Bracket, Oil Cooler and Oil Pressure Switch
Oil Filter Bracket, Oil Cooler and Oil Pressure Switch, Engine Codes CJDA, CJDD
Assembly Overview - Oil Filter Bracket and Oil Cooler
Removing and Installing Oil Filter Bracket Together with Oil Cooler
Checking Oil Pressure and Oil Pressure Switch -F1
Oil Filter Bracket, Oil Cooler and Oil Pressure Switch, Engine Codes CPYA, CPYB, CPYC
Cpyd, Cpye
Assembly Overview - Oil Filter Bracket, Oil Cooler
Removing and Installing Oil Filter Bracket with Engine Oil Cooler
Removing and Installing Oil Cooler
Removing and Installing Oil Pressure Switch -F1
Checking Oil Pressure and Oil Pressure Switch -F1
Cooling
Removing and Installing Parts of Cooling System
Parts of Cooling System, Engine Side, Engine Codes CJDA, CJDD
Parts of Cooling System, Engine Side, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Coolant Hose Schematic Diagram
Cooling System: Check Frost Protection and Coolant Level
Checking Frost Protection, Replenishing Coolant Additive if Necessary
Checking Coolant Level, Replenishing Coolant Additive if Necessary
Mixture Ratio
Draining and Filling Coolant
Draining
Filling
Cpye
Cpye
Removing and Installing 4/2-Way Valve with Thermostat
Checking Cooling System for Leaks
Checking Oil Cooler for Leaks
Engine Codes CJDA, CJDD
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Fuel Supply System
Removing and Installing Parts of Fuel Supply System
Safety Precautions When Working on Fuel Supply System
Rules for Cleanliness
Procedure When Filling with Incorrect Fuel
Step 1 (Engine was Started with Incorrect Fuel)
Step 2 (Engine was Not Started with Incorrect Fuel)
Step 3 (There Are Filings in Fuel Tank and Strainer)
Step 4 (There Are no Filings in Fuel Tank and Strainer)
Step 5 (There Are Filings in High-Pressure Pump)
Step 6 (There Are no Filings in High-Pressure Pump)
Assembly Overview - Fuel Filter
Engine Codes CJDA, CJDD
Upper Part of Fuel Filter
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Draining Water from Fuel Filter/Fuel Tank
Renewing Fuel Filter
Renewing Fuel Filter or Upper Part of Fuel Filter CJDA, CJDD
Renewing Fuel Filter, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Removing and Installing Supplementary Fuel Pump -V393- (Inline Electronic Fuel Pump)
Checking Components and Functions
Checking Supplementary Fuel Pump -V393- (Inline Electronic Fuel Pump)
Checking Accelerator Pedal Position Sender -G79-, if Fitted
Turbocharging/Supercharging
Charge Air System with Turbocharger
Safety Precautions When Working on Charge Air System with Turbocharger
Rules for Cleanliness
Assembly Overview - Turbocharger with Attachments
Engine Codes CJDA, CJDD
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Removing and Installing Turbocharger
Removing
Installing
Checking Charge Air System
Checking Charge Air System for Leaks
Checking Charge Pressure Control
Connection for Vacuum Hoses
Engine Codes CJDA, CJDD
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
Intake System, Installation Position
Intake System, Installation Position
Testing Vacuum System
Checking Supply Line and Non-Return Valve (Engine Codes CJDA, CJDD Only)
Checking Control Line to Turbocharger, Engine Codes CJDA, CJDD, CPYA, CPYB, CPYC
Cpyd, Cpye
Checking Vacuum Hoses
Checking Components and Functions
Markings on Air Mass Meter and on Elbow of the Intake Connecting Pipe, View from Tur- Bocharger End
Cpya, Cpyb, Cpyc, Cpyd, Cpye
Checking Charge Pressure Sender -G31
Checking Position Sender for Charge Pressure Positioner -G581
Checking Exhaust Gas Temperature Sender 1 -G235- (Exhaust Gas Temperature Sender Ahead of Turbocharger)
Mixture Preparation - Injection
Repairing Diesel Direct Injection System
Instructions for Working on Fuel System
To Avoid any Risk of Injuries to Persons And/Or the Destruction of the Injection and Glow Plug System, the Following Must be Noted
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Engine Data
Download this manual
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
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