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Volkswagen CPYC User Manual
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3.2.1
Assembly overview - oil filter bracket, oil
cooler
Caution
Seals 1
1 and 14 must not be lubricated with oil. The coolant
seals would otherwise swell up.
3
Industriemotoren - Industrial Engines 2009 
â–¶
Workshop Manual for Diesel Engine (2.0 l/36-75 kW_EA
189) 05.2015
266
Repair Group 17 - Lubrication
281
283
Table of Contents
Default Chapter
3
Table of Contents
3
Technical Data
17
Description of Symbols
17
Important Notes for Repair Work on the Engine
17
General Safety Notes
19
Technical Data
21
Engine Number/Engine Code
21
Engine Data
22
Service Work
26
Entries in Service History Book
26
Service Intervals
27
Countries with High Sulphur Content in Diesel Fuel
28
Severe Operating Conditions
29
Extended Service Intervals
29
Scope of Interval Service
30
General Scopes of Service
30
Additional Work
32
Scopes of Service for Gas Systems
33
Descriptions of Work, Engine, General
34
Engine and Add-On Parts in Engine Compartment (from above and Below): Perform Visual Check for Leaks and Damage
34
Perform Road Test
34
Add-On Parts on the Engine Peripherals
35
Warranty
35
Repair Work - Important Information
35
Warranty Terms
35
Vehicle Self-Diagnosis
38
Features of Vehicle Self-Diagnosis
38
Technical Data of Vehicle Self-Diagnosis
38
Read Version of Engine Control Unit
38
Available Diagnosis Functions When Using the Vehicle Diagnosis, Testing and Information System
39
Connecting Vehicle Diagnostic Tester and Selecting Engine Control Unit
39
Connecting Test Box to Check Lines
40
Connecting Test Box -V.A.G 1598/42- Using Adapter Cable -V.A.G 1598/39-1
41
Connecting Test Box -V.A.G 1598/42- Using Adapter Cable -V.A.G 1598/39-2
42
Event Memory
42
Reading Event Memory
42
Clearing Event Memory
43
List of Fault Codes
44
Fault Code: 00022/P0016
46
Fault Code: 00257/P0101
50
Fault Code: 04110/P100E
80
Fault Code: 08320/P2080
86
Fault Code: 13256/P33C8
103
Fault Code: 49153/U0001
104
Final Control Diagnosis
105
Performing Final Control Diagnosis
105
Measured Value Blocks, Engine Codes CJDA, CJDD
109
Safety Precautions
109
Reading Measured Value Block
110
Evaluating Measured Value Blocks at Idling Speed
111
Display Group 1 - Injected Quantity
111
Display Group 2 - Idling Speed
112
Display Group 3 - Exhaust Gas Recirculation
113
Display Group 4 - Activation of Injectors -N30
113
Display Group
113
Display Group 7 - Temperatures
114
Display Group 10 - Air Quantities
114
Display Group 11 - Charge Pressure Control
115
Display Group 12 - Status
115
Display Group 13 - Smooth Running Control 1
117
Display Group 20 - Fuel Rail Values 3
117
Display Group 20 - Fuel Rail Values
117
Display Group 30 - Pedal Encoder
118
Display Group 34 - Charge Pressure Positioner
119
Display Group 99 - Exhaust Gas Temperature Sender
119
Display Group
119
Display Group 100 - Diesel Particulate Filter, Exhaust Gas Temperature Sender, Pressure Differential Sender
120
Display Group 106 - Diesel Particulate Filter, Regeneration 6
121
Display Group 108 - Diesel Particulate Filter, Regeneration 8
121
Evaluating Measured Value Blocks at Full Load
122
Conditions for Measurements at Full Load
122
Display Group 1 - Injected Quantity
122
Display Group 104
122
Display Group 3 - Exhaust Gas Recirculation
123
Display Group 8 - Torque Limit 1
124
Display Group 11 - Charge Pressure Control
125
Measured Value Blocks, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE, CPYF
125
Cpyg
125
Safety Precautions
126
Reading Measured Value Block
126
Display Group 245
130
Display Group
135
Display Group 250
136
Display Group 253
136
Display Group 254
138
Evaluating Measured Value Blocks at Full Load (Engine Code CPYA)
141
Conditions for Measurements at Full Load
141
Display Group 1 - Injected Quantity
142
Display Group 3 - Exhaust Gas Recirculation
143
Display Group 8 - Torque Limit 1
144
Display Group 11 - Charge Pressure Control
144
Evaluating Measured Value Blocks at Full Load (Engine Code CPYB)
145
Conditions for Measurements at Full Load
145
Display Group 1 - Injected Quantity
146
Display Group 3 - Exhaust Gas Recirculation
146
Display Group 8 - Torque Limit
147
Display Group 11 - Charge Pressure Control
148
Removing and Installing Engine
149
Notes on Removing
150
Securing Engine to Assembly Stand
152
Notes on Installing
152
Specified Torques
153
Additional Information and Assembly Work for Power Units with Air Conditioning System
153
Crankshaft Group
154
Dismantling and Assembling Engine
154
Assembly Overview - Poly V-Belt Drive, with Air Conditioner Compressor
156
Assembly Overview - Poly V-Belt Drive, Without Air Conditioner Compressor
157
Removing and Installing or Renewing Poly V-Belt
157
Poly V-Belt: Check Condition
159
Removing and Installing Poly V-Belt Tensioner, Engines with Air Conditioner Compressor Only
159
Removing and Installing Ancillary Bracket
160
Assembly Overview - Toothed Belt Drive, Engine Codes CJDA, CJDD, Without Crankshaft Seal
162
Removing and Installing Engine Bracket
164
Assembly Overview - Toothed Belt Drive, Engine Codes CPYA, CPYB, CPYC, CPYE, with Crankshaft Seal
165
Removing and Installing Toothed Belt Guard with Inspection Cover for Checking Tension of Toothed Belt
166
Performing Visual Check of Toothed Belt Tension
167
Assessing Wear on Tensioning Roller and Belt Pulleys
168
Wear of High-Pressure Pump Pulley
168
Assessing Wear
169
Removing and Installing Crankshaft Protective Cover
171
Assembly Overview - Crankcase, Engine Codes CJDA, CJDD
172
Assembly Overview - Crankcase, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
173
Removing and Installing Sealing Flange and Flywheel
174
Assembly Overview - Sealing Flange, Belt Pulley End
175
Renewing Crankshaft Oil Seal - Pulley End
177
Removing
178
Installing
179
Removing and Installing Crankshaft Sealing Flange, Pulley End
180
Removing
181
Installing
182
Assembly Overview - Sealing Flanges and Flywheel
183
Renewing Crankshaft Sealing Flange - Flywheel End
185
Pressing out Sealing Flange with Sender Wheel
187
Pressing in Sealing Flange with Sender Wheel
188
A - Assembling Seal with Sender Wheel on Assembly Tool -T10134
188
B - Installing Assembly Tool -T10134- with Sealing Flange to Crankshaft Flange
190
C - Bolting Assembly Tool -T10134- to Crankshaft Flange
191
D - Pressing Sender Wheel Onto Crankshaft Flange Using Assembly Tool -T10134
192
E - Checking Installation Position of Sender Wheel on Crankshaft
192
F - Re-Pressing Sender Wheel
193
Removing and Installing Engine Speed Sender -G28
194
Removing
194
Installing
194
Removing and Installing Crankshaft
195
Assembly Overview - Crankshaft
196
Crankshaft Dimensions
196
Pulling Needle Bearing, if Fitted, out of and Driving into Crankshaft
197
Pulling out
197
Driving in
198
Dismantling and Assembling Pistons and Conrods
198
Assembly Overview - Pistons and Conrods
199
Separating New Conrods
201
Bearing Shells - Installation Position
202
Checking Piston Projection at TDC
203
Piston and Cylinder Dimensions
204
Cylinder Head, Valve Gear
205
Cylinder Head
205
Assembly Overview - Cylinder Head
206
Removing and Installing Hall Sender -G40
207
Assembly Overview - Cylinder Head Cover, Engine Codes CJDA, CJDD
210
Removing and Installing Cylinder Head Cover
212
Assembly Overview - Cylinder Head Cover, Engine Codes CPYA, CPYB, CPYC, CPYD
218
Cpye
218
Removing and Installing Cylinder Head Cover
221
Renewing Toothed Belt and Toothed Belt Tensioning Roller for Camshaft Drive, Engine Co- des CJDA, CJDD, CPYA, CPYB, CPYC, CPYD, CPYE
226
Removing
228
Installing, Tensioning
230
Checking Compression
234
Removing and Installing Cylinder Head
236
Notes on Removing
237
Notes on Installing
241
Removing and Installing Vacuum Pump
242
Repairing Valve Gear
243
Assembly Overview - Valve Gear
244
Valves
245
Valve Dimensions
245
Checking Valve Guides
245
Renewing Valve Stem Seals
246
Removing and Installing Camshaft
249
Removing
250
Installing
251
Removing and Installing Camshaft Oil Seal
255
Engines up to
256
Engines as of
258
Lubrication
260
Engine Oil
260
Engine Oil Level: Check
260
Engine Oil: Draining or Extracting; Renewing Oil Filter and Replenishing Engine Oil
260
Draining or Extracting Engine Oil
261
Renewing Engine Oil Filter, Engine Codes CJDA, CJDD, CPYA, CPYB, CPYC, CPYD
261
Cpye
262
Replenishing Engine Oil
263
Parts of Lubrication System
265
Assembly Overview - Oil Pump, Sump
266
Engine Codes CJDA, CJDD
267
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
270
Removing and Installing Sump
273
Removing
274
Installing
275
Oil Filter Bracket, Oil Cooler and Oil Pressure Switch
276
Oil Filter Bracket, Oil Cooler and Oil Pressure Switch, Engine Codes CJDA, CJDD
276
Assembly Overview - Oil Filter Bracket and Oil Cooler
277
Removing and Installing Oil Filter Bracket Together with Oil Cooler
278
Checking Oil Pressure and Oil Pressure Switch -F1
280
Oil Filter Bracket, Oil Cooler and Oil Pressure Switch, Engine Codes CPYA, CPYB, CPYC
281
Cpyd, Cpye
281
Assembly Overview - Oil Filter Bracket, Oil Cooler
282
Removing and Installing Oil Filter Bracket with Engine Oil Cooler
284
Removing and Installing Oil Cooler
286
Removing and Installing Oil Pressure Switch -F1
289
Checking Oil Pressure and Oil Pressure Switch -F1
290
Cooling
292
Removing and Installing Parts of Cooling System
292
Parts of Cooling System, Engine Side, Engine Codes CJDA, CJDD
294
Parts of Cooling System, Engine Side, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
295
Coolant Hose Schematic Diagram
296
Cooling System: Check Frost Protection and Coolant Level
296
Checking Frost Protection, Replenishing Coolant Additive if Necessary
297
Checking Coolant Level, Replenishing Coolant Additive if Necessary
298
Mixture Ratio
299
Draining and Filling Coolant
300
Draining
300
Filling
301
Cpye
303
Cpye
304
Removing and Installing 4/2-Way Valve with Thermostat
306
Checking Cooling System for Leaks
308
Checking Oil Cooler for Leaks
309
Engine Codes CJDA, CJDD
310
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
312
Fuel Supply System
314
Removing and Installing Parts of Fuel Supply System
314
Safety Precautions When Working on Fuel Supply System
315
Rules for Cleanliness
316
Procedure When Filling with Incorrect Fuel
317
Step 1 (Engine was Started with Incorrect Fuel)
317
Step 2 (Engine was Not Started with Incorrect Fuel)
318
Step 3 (There Are Filings in Fuel Tank and Strainer)
318
Step 4 (There Are no Filings in Fuel Tank and Strainer)
319
Step 5 (There Are Filings in High-Pressure Pump)
319
Step 6 (There Are no Filings in High-Pressure Pump)
320
Assembly Overview - Fuel Filter
320
Engine Codes CJDA, CJDD
320
Upper Part of Fuel Filter
321
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
323
Draining Water from Fuel Filter/Fuel Tank
323
Renewing Fuel Filter
324
Renewing Fuel Filter or Upper Part of Fuel Filter CJDA, CJDD
325
Renewing Fuel Filter, Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
328
Removing and Installing Supplementary Fuel Pump -V393- (Inline Electronic Fuel Pump)
329
Checking Components and Functions
330
Checking Supplementary Fuel Pump -V393- (Inline Electronic Fuel Pump)
330
Checking Accelerator Pedal Position Sender -G79-, if Fitted
332
Turbocharging/Supercharging
335
Charge Air System with Turbocharger
335
Safety Precautions When Working on Charge Air System with Turbocharger
336
Rules for Cleanliness
336
Assembly Overview - Turbocharger with Attachments
337
Engine Codes CJDA, CJDD
338
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
340
Removing and Installing Turbocharger
342
Removing
343
Installing
345
Checking Charge Air System
346
Checking Charge Air System for Leaks
347
Checking Charge Pressure Control
349
Connection for Vacuum Hoses
350
Engine Codes CJDA, CJDD
351
Engine Codes CPYA, CPYB, CPYC, CPYD, CPYE
352
Intake System, Installation Position
352
Intake System, Installation Position
353
Testing Vacuum System
354
Checking Supply Line and Non-Return Valve (Engine Codes CJDA, CJDD Only)
354
Checking Control Line to Turbocharger, Engine Codes CJDA, CJDD, CPYA, CPYB, CPYC
355
Cpyd, Cpye
355
Checking Vacuum Hoses
356
Checking Components and Functions
356
Markings on Air Mass Meter and on Elbow of the Intake Connecting Pipe, View from Tur- Bocharger End
357
Cpya, Cpyb, Cpyc, Cpyd, Cpye
357
Checking Charge Pressure Sender -G31
359
Checking Position Sender for Charge Pressure Positioner -G581
361
Checking Exhaust Gas Temperature Sender 1 -G235- (Exhaust Gas Temperature Sender Ahead of Turbocharger)
363
Mixture Preparation - Injection
366
Repairing Diesel Direct Injection System
366
Instructions for Working on Fuel System
367
To Avoid any Risk of Injuries to Persons And/Or the Destruction of the Injection and Glow Plug System, the Following Must be Noted
369
4
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Volkswagen CPYC Specifications
General
Brand
Volkswagen
Model
CPYC
Category
Engine
Language
English
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